About SLS printing and Cold Metal Fusion CMF, Cold Ceramic Fusion CCF, and Cold Exotic Powders Fusion CEPF

Selective Laser Sintering (SLS) is widely used in additive manufacturing for polymers and, in modified forms, for metals and ceramics. However, conventional SLS and laser melting routes impose significant thermal, material and process limitations, particularly when working with non-standard, fragile or highly functional powders.

3Dresyns has developed binder-based powder systems that enable an alternative SLS approach:
Cold Metal Fusion (CMF), Cold Ceramic Fusion (CCF) and Cold Exotic Powders Fusion (CEPF).

These technologies enable direct, mold-free additive manufacturing of ceramic, metal, polymer and exotic powder materials without full laser melting, significantly expanding material compatibility and process robustness.

From Conventional SLS to Cold Fusion Technologies

In conventional SLS and laser-based metal AM:

  • Powders are partially or fully melted by high-energy lasers

  • High thermal gradients induce residual stresses and distortions

  • Material selection is limited to laser-compatible powders

  • Process control becomes complex and energy-intensive

Cold fusion technologies developed by 3Dresyns take a fundamentally different approach.

Instead of relying on full melting, powders are selectively bonded using bio-based binder powders, while the laser provides shape definition rather than complete material fusion.

This approach preserves geometry during printing and shifts densification to controlled post-processing steps.

What Is Cold Metal, Ceramic and Exotic Powders Fusion?

Cold fusion SLS processes rely on:

  • Physical mixing of functional powders with binder powders

  • Selective laser activation to build the green part

  • Shape retention without molds or tooling

  • Subsequent debinding and sintering to achieve final properties

Because printed parts retain their shape after printing, these processes qualify as direct additive manufacturing, while avoiding many limitations of thermal melting routes.

Cold Fusion Technologies by 3Dresyns

Cold Metal Fusion (CMF)

Direct SLS printing of metal powders using binder-based cold fusion, followed by controlled debinding and sintering.

Enables:

  • Broader metal powder compatibility

  • Reduced thermal stress during printing

  • Improved dimensional control

Cold Ceramic Fusion (CCF)

SLS printing of technical ceramic powders using binder systems compatible with high-temperature sintering.

Enables:

  • Printing of advanced ceramics not suitable for photopolymers

  • High shape fidelity prior to sintering

  • Integration with established ceramic processing routes

Cold Exotic Powders Fusion (CEPF)

SLS-based printing of non-conventional and functional powders, including:

  • Nanoparticles and nanowires

  • Microfibers

  • Functional fillers and hybrid materials

This enables additive manufacturing of materials that are otherwise extremely difficult or impossible to process using conventional AM technologies.

3Dresyns Bio-Based Binder Powders for Cold SLS Printing

3Dresyns develops universal, non-photoreactive, bio-based binder powders designed for cold SLS fusion of:

  • Ceramics

  • Metals

  • Polymers and high-performance plastics

  • Exotic and functional powders or fibers

These binder powders are designed for easy physical mixing, without the need for complex chemical surface treatments.

Key Features of 3Dresyns Cold SLS Binder Powders

3Dresyns binder powders for CMF, CCF and CEPF exhibit the following features:

  • Universal compatibility with a wide range of powders and fibers

  • Water- or solvent-soluble debinding options

  • Bio-based formulations with > 90% bio content

  • Simple dry powder mixing using low-cost equipment

  • Excellent adhesion, uniformity and stability after mixing

  • No gravitational separation with micron and submicron powders

  • Powder loadings up to ~60 vol % (lower for nanoparticles and fibers)

  • Printable on most polymer powder SLS printers

Debinding, Sintering and Dimensional Control

After printing, cold fusion parts undergo controlled debinding and sintering, using:

  • Water debinding

  • Eco-friendly solvent debinding (e.g. EDS1 Bio at 90 °C)

  • Thermal debinding and sintering

Key process advantages include:

  • Controlled and reproducible shrinkage

  • Low expansion coefficients to minimize micro-fractures

  • Reduced risk of cracking during post-processing

Final resolution can reach ~50 microns, depending on the particle size of the selected powder or fiber.

Advantages of Cold Fusion SLS Technologies

Compared to conventional SLS and laser melting routes, cold fusion technologies offer:

  • Expanded material compatibility

  • Lower thermal stress during printing

  • Mold-free, direct additive manufacturing

  • Improved dimensional stability

  • Reduced process complexity

  • Access to exotic and functional materials

These advantages make cold fusion SLS particularly suitable for R&D, functional prototyping and advanced manufacturing applications.

Typical Applications

Cold Metal, Ceramic and Exotic Powders Fusion technologies are used in applications such as:

  • Technical ceramic and metal components

  • Functional polymer and composite parts

  • Parts incorporating nanomaterials or fibers

  • Research and experimental materials

  • Advanced functional devices

Customization and Process Development

Cold fusion processes are highly material- and application-dependent.

3Dresyns supports customers through:

  • Binder powder selection and customization

  • Optimization of powder ratios and mixing

  • Debinding and sintering process development

  • Dimensional control and shrinkage tuning

  • Technology transfer from lab to production

Final Note

Cold fusion SLS technologies fundamentally expand what can be achieved with powder-based additive manufacturing.

If you are working with ceramic, metal, polymer or exotic powders that are not compatible with conventional SLS or laser melting, 3Dresyns can support you with binder-based cold fusion solutions engineered for your specific materials and applications.

Contact us to discuss your SLS cold fusion process or powder system requirements.