As additive manufacturing continues to revolutionize industries, laser sintering is breaking free from its aerospace roots — one of the first business segments to embrace and benefit from its potential — and is fulfilling new applications across various sectors. RMB Products offers customers its knowledge base developed over more than 20 years of employing laser sintering to meet exact specifications in the aerospace industry. It’s also expanding its laser sintering services to help transform other manufacturing sectors.
Laser sintering, also known as additive manufacturing, uses 3D printing techniques based on CAD-generated designs to create three-dimensional objects by adding material layer by layer. This technology forms a key pillar of Industry 4.0, offering a manufacturing potential unlike any previous technology.
This process can more easily create parts with complex geometry and internal structures that would be difficult or impossible to produce using conventional techniques. Among its many advantages, laser sintering enables iterative design, faster production times, and potentially significant cost savings. As an additive opposed to a subtractive manufacturing process, companies can realize reduced material waste sent to a landfill, simplified production processes and costs related specifically to material used in production, not excess, discarded material.
Other advantages of laser sintering that might apply to various industries include:
Perhaps the most promising frontier for laser sintering lies in the semiconductor industry. Semiconductor manufacturers can tap into $52 billion in funding from the CHIPS Act,1 a landmark government investment designed to bolster domestic semiconductor manufacturing. The funding enables semiconductor manufacturers to explore new technologies to solve complex challenges, such as additive manufacturing. The funding potentially allows this country to reclaim a significant portion of chip production dominated by South Korea and Taiwan since 2017, despite the technology’s American origins.
One of the key advantages offered by laser sintering is its ability to produce intricate machine components with internal geometries that would be impossible — or prohibitively expensive — to create with traditional manufacturing methods. Laser sintering allows the production of net-shape parts that significantly slash wasted material, a bonus in an industry that prioritizes precision and purity.
Slashing waste through laser sintering improves product purity in the semiconductor industry in several ways:
Laser sintering addresses these factors, so its waste reduction capabilities directly contribute to maintaining and improving product purity.
RMB’s work with high-temperature materials like polyetheretherketone (PEEK) is opening new doors for applications such as wafer handlers and end effectors. These components demand exceptional dimensional stability and performance under extreme conditions, and RMB’s additively manufactured parts are proving to be strong contenders against established materials like Vespel® Polyimide.
Additive manufacturing techniques, such as laser sintering, are particularly valuable for small-volume, highly specialized components where traditional manufacturing methods may be challenging or cost prohibitive. This manufacturing method excels in such scenarios.
Postproduction capabilities comprise an essential aspect of comprehensive service for parts manufacturing for the semiconductor market. For example, RMB offers vapor smoothing, a surface treatment integral to realizing the exacting standards required in semiconductor manufacturing. Treatments such as vapor smoothing enable semiconductor fabs to combine the benefits of laser sintering’s flexibility with the necessary surface quality and purity.
Chemical vapor smoothing is an important postprocessing technique in additive manufacturing and is particularly valuable for semiconductor applications. In specialized equipment and environments, part surfaces are smoothed out while being exposed to a vapor. RMB has developed significant expertise in this area, including pioneering vapor smoothing with challenging materials that had not previously been sintered
When a part emerges from the laser sintering manufacturing process, the surface is akin to 80-grit sandpaper, and vapor smoothing offers controllable levels of smoothness for the desired finish. This process not just smooths the part’s surface but also increases the part’s overall strength. Interestingly, it can improve elongation when applied to materials such as polyamide 12 (PA 12).
In the semiconductor industry, with a purity imperative, vapor smoothing provides a notable advantage. The smoother surfaces are less likely to trap contaminants, helping meet the exacting standards of semiconductor manufacturing.
Environmentally friendly media, using safe solvents — particularly for vapor smoothing of PVDF — is more user-friendly and aligns with modern sustainability goals. In short, laser sintering combined with the proper post-production finishing treatment can supply:
The ability to work with advanced materials is a game changer for laser sintering in new industries. For instance, RMB is the only company in the Western Hemisphere capable of laser sintering PVDF, a fluoropolymer with excellent chemical resistance and thermal stability. This capability has generated significant interest in the semiconductor industry, where PFA concerns have driven a search for safer alternatives. RMB regularly works with polymers that adhere to the high-purity standards within the semiconductor industry.
As laser sintering expands into new industries, education is a critical component. Many potential customers are unfamiliar with designing for additive manufacturing. RMB is actively working with companies to help them understand the design benefits of this technology.
This education includes lending guidance to customers uncertain of the best methods for writing specifications for parts destined for additive manufacturing. RMB can help identify which components make the best candidates for laser sintering while managing customer expectations.
The primary factor limiting the size of laser-sintered parts is the build chamber size of the 3D printer. Commercial machines typically have built volumes ranging from a few hundred millimeters to around 1 meter in each dimension. This physical constraint of the build chamber sets the maximum possible dimensions for a single part that can be produced in one print job.
While the build volume of laser sintering machines can be a limitation, RMB has developed techniques to overcome this constraint. For larger components, the staff can bond multiple laser-sintered parts together, creating assemblies that exceed the size of the build platform. This capability, combined with RMB’s expertise in hot gas welding (certified to European standards), allows the company to produce larger, more complex parts without sacrificing the benefits of additive manufacturing.
What sets RMB apart in the expanding world of laser sintering is the company's production-first mentality. Unlike many prototyping houses that have attempted to scale up to production, RMB began with a focus on manufacturing at scale. This approach means RMB brings a deep understanding of producibility, materials science, and quality control to every project — even at the prototype stage.
RMB's vertical integration, combining polymer science expertise with manufacturing knowledge, allows the company to tackle challenges that others in the industry can't. For example, RMB's ability to modify material morphology has enabled the company to successfully laser sinter materials that other providers struggle with, such as PVDF. RMB strives to obtain and maintain certifications that assure customers of its commitment to the highest quality standards across manufacturing processes.
As demand grows, particularly in the semiconductor sector, RMB is exploring the possibility of moving its laser sintering operations into clean room environments. This step would further enhance the company's ability to meet the stringent requirements of high-purity applications.
RMB’s partnerships with industry leaders like EOS GmbH underscore the company's position at the edge of laser sintering technology. As the only service bureau in the Western Hemisphere for certain high-tech materials, RMB is uniquely positioned to drive innovation in this rapidly evolving field.
As laser sintering expands beyond its aerospace origins, it’s ushering in a new era of manufacturing possibilities. From semiconductors and medical devices to automotive prototyping and fuel cell development, the applications for this technology are limited only by the engineer’s imagination.
Looking to the future, one thing is clear: Laser sintering is a versatile, powerful tool that's transforming manufacturing across industries, and RMB is proud to be leading the charge. Request a quote to get started on your next laser sintering project.