Selective Laser Sintering (SLS) is a Direct Digital Manufacturing (DDM) process that does not involve tooling. The benefits of the process increase as the complexity of the design increases. This runs counter to traditional manufacturing processes where additional design complexity usually involves greatly increased time and expense.

SLS production is economically viable for low complexity designs only when the production volume is so low that tooling and other NRE expenses cannot be amortized over a large volume of parts. At the other end of the extreme, SLS production can be economically viable for even large production volumes if the design is of sufficient complexity that it would be difficult or impossible to fabricate the part with any other method. SLS also becomes more viable if the product design is subject to change going into manufacturing and avoids the additional costs and delays of tooling changes.

As with any fabrication process, the maximum benefit is achieved if the design itself takes the manufacturing process into account. For example, the duct assembly shown below included five custom components, fifteen fasteners, adhesives and multiple assembly steps prior to being redesigned for SLS production. The assembly has been replaced with a single SLS production part, resulting in fewer components, reduced weight, increased strength and no need for assembly.

Clearly, designing parts for SLS production has significant advantages in that many limitations of traditional manufacturing do not exist.