Projects & applications
Where polymer SLS earns its place
Application areas for polymer laser sintering, organized by the job a part has to do: from UAV airframe parts to robotic grippers and production fixtures. Verified case studies will be published here once a project is complete and the customer has approved publication.
Applications by function
Eight application areas, organized by function
Each area lists example parts and the sectors where they typically appear. Suitability is always confirmed for the specific part in an engineering review.
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Lightweight structures
Load-carrying parts where every gram counts. Hollow sections, ribs and topology-optimized shapes place material along the load paths, free of the constraints of machining or molding.
Example parts
- Airframe nodes and arm joints
- Structural brackets
- Robot arm covers
- Lightweight fixtures
Typical sectors
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Housings and enclosures
Enclosures that carry their own screw bosses, clips, cable exits and ventilation, built without draft angles or tooling.
Example parts
- Avionics and electronics enclosures
- Sensor and camera housings
- Controller enclosures
- Battery covers
Typical sectors
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Ducts and fluid routing
Air ducts, manifolds and channels with bends, flanges and branches in one piece, where a machined or molded design would need several components.
Example parts
- ECS duct prototypes
- Vacuum manifolds
- HVAC and intake ducts
- Cooling air guides
Typical sectors
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Jigs, fixtures and tooling
Production aids shaped exactly to the part they hold, check or protect, light enough to handle and quick to revise.
Example parts
- Assembly jigs
- Drilling and inspection fixtures
- Locating nests
- Masking and trim templates
Typical sectors
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Snap-fits and functional assemblies
Clips, hinges and snap-fits that rely on the toughness of polyamide, and assemblies with moving parts built in one piece where the clearances allow it.
Example parts
- Harness clips and retainers
- Snap-fit lids and covers
- Hinges and latches
- Cable guides
Typical sectors
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Lattices and energy absorption
Lattice structures tune stiffness against weight. Made in an elastomer such as TPU, they can absorb impacts or spread pressure.
Flexible material: TPU Status: Planned
Example parts
- Lattice-filled cores
- Protective bumpers
- Landing feet and skids
- Damping elements
Typical sectors
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Spare and replacement parts
Polymer parts that are discontinued, hard to source or needed in very small numbers, built to order from CAD data or drawings.
Example parts
- Machine spare parts
- Conveyor guides and wear parts
- Knobs, covers and housings
- Parts for legacy equipment
Typical sectors
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Functional prototypes
Prototypes in an engineering polyamide that can be assembled, loaded and tested, not only looked at.
Example parts
- Fit and installation prototypes
- Test rig components
- Pre-series parts
- Design review models
Typical sectors
Regulated flight applications
Parts intended for certified or regulated flight applications need qualification and approvals that go beyond manufacturing. Tell us the intended use in your request and we will be clear about what we can and cannot support.
Case studies
Verified case studies will be published here
We publish a project only when it is complete and the customer has approved publication, with real parts, real photographs and technical details. Until then, this page describes application areas, not finished customer work.
How we protect your designsEach case study will include
- The part and the job it does
- Material, build orientation and finishing
- Decisions from the engineering review
- Photographs of the produced parts
- Customer approval before publication
Start a project
Have a part in mind?
Send CAD files or drawings. An engineer reviews manufacturability, material and orientation before we quote, and your files stay confidential.