What part orientation strategy minimizes thermal stresses during the sintering process in SLS?

The part orientation strategy that minimizes thermal stresses during the sintering process in SLS (Selective Laser Sintering) is to orient parts so their longest dimension is parallel to the scanning direction and to distribute the part's cross-sectional area as evenly as possible within each layer. Orienting the longest dimension parallel to the scanning direction reduces the cumulative heat input along that axis during the sintering process. This helps minimize warping and distortion because the material is heated more uniformly. Distributing the cross-sectional area evenly across each layer ensures consistent heat dissipation throughout the build, preventing localized hot spots and reducing thermal gradients. Steep overhangs or large solid sections in a single layer can create significant thermal stresses as they cool at different rates than surrounding areas. Therefore, careful consideration of part orientation and its impact on heat distribution is crucial for minimizing thermal stress and achieving accurate, dimensionally stable parts in SLS.