Instructions for Use (IFU) for SLS Cold Fusion of Metal, Ceramic and E

This document provides technology-specific instructions for the use of 3Dresyns® binder and auxiliary systems for Selective Laser Sintering (SLS) and cold fusion–type powder processing workflows, including metal, ceramic, polymer and exotic powder systems.

Discover our eco Powder Binders for SLS printing of metal, ceramic, polymer and exotic powders using Cold Metal Fusion (CMF), Cold Ceramic Fusion (CCF), Cold Polymer Fusion (CPF) and Cold Exotic Materials Fusion.

For more background, read: About Cold Metal Fusion (CMF), Cold Ceramic Fusion (CCF), Cold Polymer Fusion (CPF), and Cold Exotic Materials Fusion.

This IFU applies to powder-based fusion workflows and is fundamentally different from IFUs for vat photopolymerization technologies.

This IFU must be used in conjunction with

Printer- and equipment-specific documentation provided by the SLS or powder-processing system manufacturer
Any application-specific technical documentation supplied by 3Dresyns

This document does not replace manufacturer instructions for SLS equipment.

Scope of application

This IFU applies to

SLS and SLS-like powder fusion systems
Cold fusion or binder-assisted powder processing routes
Metal, ceramic and specialty powder systems

This IFU does not apply to

Vat photopolymerization (SLA, DLP, LCD)
Inkjet binder jetting unless explicitly validated
Extrusion-based or filament-based technologies

Nature of cold fusion and powder-based processes

Powder-based fusion and cold fusion workflows rely on:

Localized energy input
Particle bonding and consolidation
Subsequent thermal or post-processing steps

Final part properties depend on:

Powder composition and morphology
Binder or auxiliary system used
Energy input and scan strategy
Post-processing, debinding and sintering steps

Materials behavior in powder-based systems is highly process-dependent.

Material and powder considerations

Powders used in SLS and cold fusion workflows:

Must meet defined particle size and distribution requirements
Must be compatible with the selected binder or auxiliary system
May exhibit different flowability, packing density and thermal response

Not all powders are suitable for all fusion strategies. Compatibility must be verified experimentally.

Printing and fusion considerations

Process parameters influencing fusion behavior include:

Laser power or energy density
Scan speed and hatch strategy
Layer thickness and recoating behavior
Powder bed temperature and environment

Improper parameter selection may result in incomplete fusion, distortion or poor mechanical integrity.

Powder mixing instructions

Recommended mixing of 3D-POWDERS CF SD or WD Bio with your chosen ceramics, metals, polymers and exotic powders.

Mix the powders in a powder mixer (or similar) at room temperature to ensure full wetting and homogeneous blending:

20 wt% of 3D-POWDERS CF SD or WD Bio*
10 wt% of your chosen polymer SLS powder* (typically Nylon 12, as it is the most widely used powder in polymer SLS printers)
70 wt% of your chosen ceramic, metal, polymer or exotic powder*

Note: These percentages can be increased or decreased depending on your target properties, powder type and printer settings. Once the powder binder and polymer powder (typically Nylon 12) are fully integrated with your chosen ceramic/metal/polymer/exotic powder, the mix is ready for SLS printing. For high-performance polymers such as PEEK and PEKK (Cold Polymer Fusion), use 3D-POWDER CF5 SD Bio instead of Nylon 12.

Recommended SLS printers: SLS printer compatibility. Any open-parameter polymer SLS printer can be used.

3Dresyns can also supply custom powder blends by combining our powder binders with your selected ceramics, metals, polymers and exotic powders to meet your specifications. Contact us for quotations: info@3Dresyns.com

IFU for printing (process overview)

These fast and accurate Instructions for Use (IFU) can be used to print powder mixes for SLS Cold Metal, Ceramic, Polymer & Exotic Powders Fusion — including with low-cost SLS printers.

SLS printing process

1) Calibration (recommended)

Calibrate your powder mix by printing 3Dtest1 (3Dresyns flat coin) for rapid optimization of resolution and printing parameters.
Each SLS printer requires specific settings depending on powder composition and printer characteristics.
Slice the 3Dtest1 file using the settings of the closest equivalent polymer powder.
Send the sliced file to the printer and print.

2) Printer setup and SLS printing

Printer setup varies depending on the SLS system.
Follow the manufacturer’s manual and IFU for the equivalent polymer powder before printing.
Use the standard printing parameters of your chosen polymer powder (typically Nylon 12), but reduce the bed temperature to ~40–50–60 °C depending on the selected SLS powder binder.
If over-melting occurs, reduce energy dosage (laser power and/or scan speed) and/or slightly decrease bed temperature.

3) Post-processing

Remove parts from the build chamber.
Clean “green” parts: remove excess unfused powder manually, typically using pressurized air or a water jet (as appropriate for your material system).
If surface smoothing is needed, use Cleaning Fluid WS1.
Recycle unfused powder by filtration/sieving and reuse it by blending with fresh powder for the next jobs.

4) Debinding & sintering (for metal/ceramic systems)

Once “green” parts are fully cleaned, a debinding step is required to remove part (or all) of the binder system. After debinding, parts are referred to as “brown” parts. These are then thermally processed to remove remaining binder and sinter the metal/ceramic particles at high temperature.

Cold debinding (example)

Debind at 60–100 °C in water or in Debinding Solution EDS1 Bio (depending on the chosen SLS powder binder) for x hours (x depends on part size and geometry).

Thermal debinding & sintering (example furnace profile)

Insert the flask/parts into a preheated oven at 65 °C.
Ramp 1–2 °C/min up to 250 °C.
Hold at 250 °C for 60 minutes.
Ramp 1–2 °C/min up to 450 °C.
Hold at 450 °C for 30 minutes.
Ramp 2–5 °C/min up to the material-specific sintering temperature.
Hold at sintering temperature for 180 minutes.
Ramp down at approximately -2 °C/min.

Important: Exact debinding and sintering profiles depend on material chemistry, particle size distribution, binder selection, geometry and furnace atmosphere. Always validate your workflow for your specific powder system and target performance.

Post-processing and consolidation

Most powder-based workflows require post-processing, which may include:

Depowdering and cleaning
Debinding or solvent removal
Thermal sintering or curing steps

Post-processing conditions are critical and largely determine final density, strength and performance.

Dimensional accuracy and shrinkage

Powder-based processes often involve:

Dimensional changes during consolidation
Shrinkage during sintering or curing

Users must account for these effects during design and calibration and validate dimensional accuracy experimentally.

Handling, safety and environmental considerations

Powder handling introduces additional risks:

Dust generation
Inhalation hazards
Flammability or reactivity of certain powders

Users must follow appropriate safety procedures, including:

Personal protective equipment
Proper ventilation
Compliance with local safety and environmental regulations

Validation, qualification and responsibility

Powder fusion and cold fusion parts are highly process-dependent. Users are responsible for:

Validating process parameters for their specific powder and binder system
Qualifying post-processing workflows
Ensuring suitability for the intended application

3Dresyns does not assume responsibility for performance obtained under user-defined powder fusion workflows.

Relationship to other Instructions for Use

This IFU is specific to SLS and cold fusion powder-based processes and must not be confused with IFUs for vat photopolymerization or inkjet printing. Where binders, auxiliaries or additives are used, the relevant technical documentation applies. In case of discrepancy, the most technology-specific documentation prevails.

Governing principle

Powder-based fusion and cold fusion manufacturing are multivariable, process-driven technologies. Final material performance depends on powder characteristics, energy input, binder systems and post-processing conditions and must be validated by the user.

Instructions for Use (IFU) for SLS Cold Fusion of Metal, Ceramic and Exotic Powders