SLS and Polymer Powder Bed Fusion Additive Manufacturing

Course Number:
MFG 132
Transcript Title:
SLS and Polymer Powder Bed Fusion Additive Manufacturing
Created:
May 01, 2026
Updated:
May 01, 2026
Total Credits:
3
Lecture Hours:
0
Lecture / Lab Hours:
66
Lab Hours:
0
Satisfies Cultural Literacy requirement:
No
Satisfies General Education requirement:
No
Grading Options
A-F, P/NP, Audit
Default Grading Options
A-F
Repeats available for credit:
0

Course Description

Familiarizes students with Selective Laser Sintering (SLS) 3D printers; their functions, relevant design applications, choosing between and working with a variety of SLS materials, identifying reasons for print failures, and designing successful and repeatable print programs. Introduces SLS printer hardware, maintenance, and common subcategories of SLS printer motion and laser aperture systems. Covers different types of lasers utilized for sintering polymers, how to identify and fix common hardware issues, and how SLS printer technology has changed and improved over the years. Audit available.

Course Outcomes

Upon successful completion of this course, students will be able to:

  1. Identify models with geometry and production requirements best suited to SLS manufacturing techniques.

  2. Demonstrate appropriate machine operation and maintenance for laser-based polymer printers

  3. Measure SLS printed parts and modify printing parameters to meet tolerance specification.

  4. Calculate laser settings for different layer heights and different materials.

  5. Apply safety and PPE

Suggested Outcome Assessment Strategies

The determination of assessment strategies is generally left to the discretion of the instructor. Here are some strategies that you might consider when designing your course: writings (journals, self-reflections, pre writing exercises, essays), quizzes, tests, midterm and final exams, group projects, presentations (in person, videos, etc), self-assessments, experimentations, lab reports, peer critiques, responses (to texts, podcasts, videos, films, etc), student generated questions, Escape Room, interviews, and/or portfolios.

Department recommended assessment strategies:
  • Lecture and in-lab coaching and direct instruction.
  • Full class demonstration of skills.
  • Written exams.
  • Student proficiency through demonstration of learned strategies and skills in industry standard environments.
  • Job readiness based on performance.
  • In class lab experiments and testing using the scientific process with written result reporting.

Course Activities and Design

The determination of teaching strategies used in the delivery of outcomes is generally left to the discretion of the instructor. Here are some strategies that you might consider when designing your course: lecture, small group/forum discussion, flipped classroom, dyads, oral presentation, role play, simulation scenarios, group projects, service learning projects, hands-on lab, peer review/workshops, cooperative learning (jigsaw, fishbowl), inquiry based instruction, differentiated instruction (learning centers), graphic organizers, etc.

Department required course activities: Cooperative learning, lecture-lab based experiential learning, guided learning pathways, peer review, hands-on lab, simulation, simulation scenarios, oral presentations.

Course Content

Outcome #1: Identify models with geometry and production requirements best suited to SLS manufacturing techniques.

  • Geometry for SLS printing
  • Exposures for SLS printing materials
  • SLS powders and their uses, including nylon and TPU
  • Production density in SLS

Outcome #2: Demonstrate appropriate machine operation and maintenance for laser-based polymer printers

  • SLS Maintenance Planning
  • SLS material maintenance strategies
  • Print failure root cause analysis
  • Hardware, software and consumable quality analysis and action
  • SLS setup and operation
  • SLS Calibration techniques

Outcome #3: Measure SLS printed parts and modify printing parameters to meet tolerance specification

  • Measure SLS printed materials across appropriate geometry
  • SLS printing parameters for geometry and tolerance
  • Data points / gather for SLS machines’
  • Layer height and powder density adjustments for SLS printing
  • Print to tolerance using geometry to advantage

Outcome #4: Calculate laser settings for different layer heights and different materials.

  • Parameter modification for different materials
  • Parameter modification for different geometries
  • Layer heights and their effectiveness
  • Settings and parameter calibration for different materials
  • Math for SLS printing parameters
  • Math for geometrical accuracy across layer height

Outcome #5: Apply safety and PPE requirements when handling polymer powder material.

  • Powder refresh rate
  • Print cleaning
  • Print post processing
  • Powder cleaning and mixing
  • PPE for SLS
  • PPE for powder handling
  • Powder handling equipment’
  • Polymer powder pre-processing
  • Polymer powder reprocessing
  • Powder quality analysis

Suggested Texts and Materials

Use of listed Texts/Materials is not required unless so noted.

Department Notes

Safety glasses are required at all times in the manufacturing lab, and are provided for students. Students may also purchase their own safety glasses from a local supplier. Long pants and closed toed shoes are required in the manufacturing labs at all times. Appropriate clothing must be worn to work in the lab (no synthetic materials, ect.). Safety requirements are covered prior to work in the lab.