What is Selective Laser Sintering (SLS)?

The Selective Laser Sintering 3D printing process is a well-known additive manufacturing method in which a high-powered laser sinters small particles of polymer powder into a solid object or structure.

Diagram showing the SLS 3D printing process by Formlabs


  • Excellent mechanical properties
  • Great accuracy and print quality
  • No need for support structures
  • Cost-efficient for large production runs
  • Production-ready


  • End-use parts
  • Short-run, bridge, or custom manufacturing
  • Functional prototyping
  • Long-lasting, durable manufacturing aids
  • Medical devices, prosthetics, and orthotics

Formlabs®’ Fuse 1 currently prints with Nylon 12 Powder, Nylon 12 GF Powder, and Nylon 11 Powder, while the Fuse 1+ 30W enables all those powders, as well as Nylon 11 CF Powder and TPU 90A.

High-Performance SLS Powders by Formlabs 

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SLS Powders


Formlabs® Nylon 11

Material: Ductile, high-impact

Nylon 11 Powder is a high performance, bio-based nylon material for functional prototyping and small batch production.

  • Ultimate Tensile Strength: 49 MPa
  • Tensile Modulus: 1.6 GPa
  • Elongation at Break (X/Y): 40%
  • Flexural Strength: 55 MPa
  • Notched Izod: 71 J/m
  • Heat Deflection Temperature (HDT) @ 1.8 MPa: 46ºC
  • For parts that need to bend or resist impact
    • Impact-resistant prototypes, jigs, and fixtures
    • Thin-walled ducts and enclosures
    • Snaps, clips, and hinges
    • Orthotics and prosthetics*


  • SLS (Selective Laser Sintering)


Formlabs® Nylon 11 CF

Material: Carbon Fiber Reinforced

Nylon 11 CF (carbon fiber) is a highly stable, high-performance material, perfect for end-use applications requiring high stiffness and superior strength.

  • Ultimate Tensile Strength:
    • X: 69 MPa
    • Y: 52 MPa
    • Z 38 MPa
  • Tensile Modulus:
    • X: 5.3 GPa
    • Y: 2.8 GPa
    • Z: 1.6 GPa
  • Elongation at Break (X/Y/Z): 9% / 15% / 5%
  • Flexural Strength: 110 MPa
  • Notched Izod: 74 J/m
  • Heat Deflection Temperature (HDT) @ 1.8 MPa: 1786ºC
  • Functional composite prototypes
  • Replacement and spare alternatives to metal parts
  • Tooling, Jigs, Fixtures
  • High-impact equipment
  • SLS (Selective Laser Sintering)

Image of a 3D printed part produced with Formlabs Nylon 12 GF

Formlabs® Nylon 12 GF

Material: Stiff, static, load-bearing

Formlabs Nylon 12 GF is a glass-filled material with enhanced stiffness and thermal resistance. This material combines the utility of Nylon 12 with the rigidity and heat resistance of glass filler.

  • Ultimate Tensile Strength: 38 MPa
  • Tensile Modulus: 2800 MPa
  • Elongation at Break (X/Y-Z): 4% – 3%
  • Flexural Strength: 56 MPa
  • Notched Izod: 36 J/m
  • Heat Deflection Temperature (HDT) @ 1.8 MPa: 113ºC

Ideal for producing functional prototypes or end-use parts for applications where structural rigidity and thermal stability are critical.

  • SLS (Selective Laser Sintering)


Formlabs® Nylon 12

Material: Rigid, Impact Resistant

Nylon 12 has high tensile strength, ductility and environmental stability. It is suitable for creating complex assemblies and durable parts with minimal water absorption.

  • Ultimate Tensile Strength: 50 MPa
  • Tensile Modulus: 1850 MPa
  • Elongation at Break (X-Y/Z): 11% / 6%
  • Flexural Strength: 66 MPa
  • Notched Izod: 32 J/m
  • Heat Deflection Temperature (HDT) @ 1.8 MPa: 87ºC
  • Functional prototypes for composite products
  • End-use industrial parts
  • Fixtures undergoing long-term sustained loading
  • Stiff structural components
  • Thermally stressed housings
  • SLS (Selective Laser Sintering)

Image shows wearables 3D printed with TPU90 form Formlabs

Formlabs® TPU 90A

Material: Tough SLS Elastomer

TPU 90A Powder provides the perfect balance of flexibility and strength, allowing you to create durable prototypes and end-use parts that are both safe for the skin and withstand daily use.


Material Properties*:

  • Ultimate Tensile Strength: X/Y: 8.7 MPa; Z-axis: 7.2 MPa
  • Tear Resistance: X/Y: 66 kN/m; Z-axis: 39 kN/m
  • Elongation at Break: X/Y: 310%; Z-axis: 110%
  • Shore Hardness: 90A


  • Samples printed with TPU 90A powder have been evaluated in accordance with ISO 10993-1:2018, and have passed the requirements for the following biocompatibility risks:
    • ISO 10993-5: 2009 Non-cytotoxic
    • ISO 10993-23:2021 Non-irritant
    • ISO 10993-10:2021 Non-sensitizer

*Material properties may vary with part geometry, print orientation and temperature.

  • Wearables and soft-touch elements
  • Gaskets, seals, masks, belts, plugs, and tubes
  • Protective sports equipment
  • Padding, dampers, cushions, and grippers
  • SLS (Selective Laser Sintering)

Formlabs® Polypropylene Powder

Polypropylene Powder offers high ductility, allowing for repeated bending and flexing while ensuring durability, without the need for inert atmospheric control.

  • Ultimate Tensile Strength: 29 MPa
  • Tensile Modulus: 1640 MPa
  • Elongation at Break (X,Y): 34%
  • Flexural Strength: 37 MPa
  • Flexural MOdulus: 1330 MPa
  • Notched Izod: 31 J/m
  • Heat Deflection Temperature @ 1.8 MPa: 58 °C

Material properties may vary with part geometry, print orientation and temperature.

  • Packaging prototypes, watertight housings, cases
  • Automotive interior components
  • Orthotics and prosthetics
  • Strong and chemically resistant fixtures, tools, and jigs
  • SLS (Selective Laser Sintering)

Cost Per Part icon

Efficient Powder Recycling Enables Material and Cost Savings.

With Formlabs® SLS 3D printers, the refresh rate of the powder is:


Refresh Rate


Recycled Powder

What is Refresh Rate?

Short answer: The capability of an SLS 3D printer to print with a mix of new and recycled powder.

How does it work?

Set the desired refresh rate on the touchscreen, and the Fuse Sift powder recovery station will automatically mix and dose powder to be reused in future prints.

Over 100,000,000 Parts Printed with Formlabs Technology

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System Compatibility