Selective laser sintering (SLS) is an additive manufacturing process that is an offshoot of stereo lithography from the 1980s. By scanning cross sections of a part in a 3D computer design, engineers are able to use high-power lasers to fuse powdered materials to make the actual part. Unmelted powder acts as a mold; the completed part is lifted away from it. “It’s like building a loaf of bread slice by slice,” says Alex Dick, vice president of operations for five-year old Northwest UAV ...

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