SLS 3D Printing — Production-Grade Nylon, No Supports
Selective Laser Sintering produces isotropic nylon parts strong enough for genuine end-use — without supports, with fine features and with surface quality straight off the machine. Forge Labs runs PA12, PA11, glass-filled, carbon-filled, TPU and PP powders out of our Sydney workshops.
Typical projects start from $500+ · Engineering & business enquiries welcome · Upload CAD, STEP & STL files for review
Manufactured in
Sydney, Australia · Quality-checked on every job
Why Forge Labs
Why SLS is the production-ready choice
Isotropic, support-free nylon parts with the surface finish and mechanical properties of real engineering polymers.
No Supports Required
Powder bed surrounds every part, so complex geometry, lattices and interlocking assemblies print without a single support.
Isotropic Strength
SLS nylon parts are equally strong in every direction — unlike FDM, you can load an SLS part along the Z axis without worry.
Production-Grade Nylon
PA12 is the industry standard for end-use additive parts — used by Airbus, BMW and medical OEMs in volumes from 1 to 100,000+.
Fine Feature Resolution
Wall thickness down to 0.7 mm, snap-fits, living hinges and engraved text all print reliably in nylon powder.
Batch Efficient
SLS builds nest dozens of parts in a single powder bed — making 50–500 piece short runs surprisingly cost-effective.
Our Workflow
How an SLS build runs
Quote from CAD
Send STEP or STL files. We nest your parts into the build volume and quote based on actual print area, not bounding box.
DFM check
We verify wall thickness, escape holes for trapped powder and feature resolution before the build kicks off.
Print & cool-down
PA12 powder is sintered layer-by-layer at ~170 °C. The build then cools slowly to prevent warping — typically a 24 hr cycle.
Depowder, bead-blast, dispatch
Parts are de-powdered, bead-blasted to a uniform satin finish, dimensionally checked and shipped.
What we deliver
Real production nylon, additive economics
PA12 powder bed · Isotropic strength · Batch-friendly economics
SLS sinters nylon powder with a CO₂ laser, one 0.1 mm layer at a time, inside a heated build chamber. Unsintered powder supports every overhang — so impossible-to-tool geometry, captured assemblies, lattices and interlocking parts all print cleanly. That's why aerospace, medical and motorsport teams reach for SLS when a part needs to perform, not just look the part.
- PA12, PA11, glass-filled, carbon-filled, TPU and PP powders in stock
- Build envelope up to 340 × 340 × 600 mm in a single piece
- Isotropic strength — no weak Z-axis bonding like FDM
- Bead-blasted matte/satin finish standard; vapour-smoothing optional
- Black-dyed parts for cosmetic consistency on consumer products
- Production batches from 1 to 5,000+ parts a year
Our 3D printing services
Explore our 3D printing services
3D Printing Services
Industrial and business 3D printing across FDM, SLA, SLS, MJF and metal — for engineers, procurement and product teams Australia-wide.
Learn more ↗SLA 3D Printing
Ultra-smooth, high-detail resin 3D printing for visual prototypes, master patterns and display models.
Learn more ↗FDM 3D Printing
Tough thermoplastic parts for jigs, housings, brackets and durable functional prototypes.
Learn more ↗Rapid Prototyping
Fast, iterative prototypes and functional parts to validate your design before committing to tooling.
Learn more ↗Low-Volume Production
Production-grade short runs from 1 to 10,000+ parts without the cost of full injection tooling.
Learn more ↗Exhibition & Display Models
Large-format 3D printed exhibition models, product display models and show pieces — printed, finished and brand-coloured.
Learn more ↗Materials
SLS powders for every job
From standard PA12 to flexible TPU and chemically-resistant polypropylene — we'll specify the right powder on your quote.
PA12 (Nylon 12)
StandardThe workhorse SLS material. Tough, chemically resistant, fatigue resistant. The default for functional and end-use parts.
PA12 Glass-Filled
StiffPA12 with 25–40% glass beads for added stiffness and thermal stability. Common for fixtures and structural housings.
PA12 Carbon-Filled
StructuralCarbon-reinforced nylon with metal-replacement stiffness and reduced weight. Used for jigs, brackets and drone parts.
PA11 (Bio-based)
ToughCastor-oil-derived nylon with superior impact strength and flexibility. Excellent for snap-fits and shock-loaded parts.
TPU (Flexible)
FlexibleSintered thermoplastic polyurethane for flexible, shock-absorbing and high-elongation parts. Shore 88A typical.
PP (Polypropylene)
ChemicalLiving-hinge capable polypropylene for fluid containers, lab equipment and chemically-resistant housings.
Industries we serve
Where SLS earns its keep
Anywhere a part needs to perform under real-world load without the cost of injection mould tooling.
Aerospace & UAV
Lightweight ducting, drone airframes, lattice brackets and weight-optimised mounts in PA12 and carbon-filled nylon.
Medical & Prosthetics
Custom orthotics, prosthetic sockets, surgical instrument handles and equipment housings in PA12.
Automotive End-Use
Production-quantity intake components, brackets, ducting and interior trim — typically 50–5,000 parts per run.
Functional Prototypes
Working models with snap-fits, living hinges and assembled components that survive real-world testing.
Manufacturing Tooling
Assembly jigs, end-of-arm tooling, robotic grippers and ergonomic shop-floor fixtures.
Consumer Products
Short-run consumer goods, sporting equipment and bridge-production parts before injection moulding is justified.
Showcase
SLS work from the powder room
PA12 SLS production batch — end-use parts straight from the bead-blast cabinet.
HP Multi Jet Fusion run alongside SLS — same nylon, different process.
The Forge Labs print floor: multiple sintering systems in continuous operation.
FAQ
Frequently asked questions
Explore more
More from Forge Labs
Ready to start your project?
Upload your file or send a quick brief — most quotes come back within 4 working hours, with parts dispatched Australia-wide from our Sydney workshops.