Selective Laser Sintering: Processing, Materials, Challenges, Applications, and Emerging Trends

Selective laser sintering (SLS) has revolutionized manufacturing by enabling the production of intricate designs with enhanced flexibility and material efficiency. The present review delves into the SLS process, its compatibility with materials such as polymers, metals, and composites, and its influence on microstructure, mechanical properties, and overall performance. It addresses challenges like dimensional accuracy, surface finish, and residual stress while highlighting applications across various industries. Additionally, the review explores emerging trends, including hybrid manufacturing and the integration of artificial intelligence, to shape future developments in SLS technology.