Design Freedom with SLS 3D Printing: Rugged Casing

Monday 13th October 2025

At CREAT3D, we’re always exploring what’s possible with Additive Manufacturing, and few technologies open up more opportunities for design freedom than Selective Laser Sintering (SLS).

Rugged Casing

Our latest in-house project, a rugged, functional casing printed on the Formlabs Fuse 1+ 30W, shows just how far that freedom can go.

Designed to be both durable and practical, the casing integrates multiple features directly into the print: hinges, airflow vents, cable clamps and ergonomic grips - all produced in a single assembly, with no tooling required.

Design Freedom

With SLS, geometry is no longer a constraint. The process allows for complex shapes, small features, assemblies and lightweight structures that maintain mechanical strength while reducing material usage, and functional mechanisms that print fully formed.

From design to assembled part, this project took under 48 hours - a powerful example of how fast engineers can move from concept to reality when using the right tools.

Complementing the Nylon 12 SLS casing and lid, flexible silicone buttons were printed on the Formlabs Form 4 to complete the unit, demonstrating how combining multiple 3D printing processes can produce a fully functional end-use product.

Fine Details In a Single Assembly

It is truly incredible what functionality you can achieve in a single printed part.

Every element of the casing was created with purpose - designed for functionality, comfort, and real-world usability.

With Selective Laser Sintering (SLS), we were able to integrate complex geometries directly into a single print, eliminating the need for multi-stage assembly or tooling. The result is a robust, fully functional part that would be difficult to achieve using traditional manufacturing methods.

• Print-in-place hinged port covers - to provide protection from dust and FOD (foreign object debris). SLS allows for functional moving parts to be printed as one complete mechanism
• Baffle vent - to allow airflow and prevent overheating of internal electronics. The intricate internal geometry of the vent would be difficult to machine and cost prohibitive to injection mould. An alternative would be to retrofit an off-the-shelf part, that adds weight, cost and an additional assembly phase.
• Integrated strap loops - for high portability and easy adjustment when in use. The position of the loops were placed exactly where needed, ensuring maximum strength without additional fixtures or hardware.
• Ergonomic handle - sculpted for maximum comfort and grip, shaped specifically to the user’s hand. This level of personalisation and organic geometry is only possible through digital design and SLS printing, removing the constraints of traditional tooling.
• Internal cable clip - printed directly inside the casing, enabling neat and secure internal cable routing. By integrating this feature into the print, the need for additional brackets or fasteners was eliminated.
• Textured cover - to reduce material usage and weight while adding a rugged, tactile surface for improved handling. With SLS, surface patterns and textures can be added into the model itself at pre-print stage, combining form and function without secondary processing.
• Silicone button pad - (this one was produced using Silicone 40A resin with SLA technology and was fixed onto the casing) to assist grip and ease of functionality. Plus it feels great! Combining SLS and SLA technologies allows us to merge rigid and soft materials, delivering a complete solution that looks, feels, and performs like a production-ready product.

Rear of the casing with a textured surface and ergonomic handle

Port with protective hinged cover

Altogether, these features highlight the design freedom, functional integration, and production efficiency that SLS offers. With no tooling, no minimum order quantities, and no assembly. The entire process, from concept to end-use part, was achieved in under 48 hours and at a fraction of the cost of traditional methods.

Casing Highlights

• Printer: Formlabs Fuse 1+ 30W SLS system with Fuse Sift and Fuse Blast
• Material: Nylon 12 Powder
• Material used: 0.234 kg (Cost of £19.89)
• Print time: 16 hours + 30 mins post-processing
• Total turnaround: <48 hours

See SLS in Action

From design to finished product, the SLS casing took less than 48 hours. See the printing and post-processing workflow in action.

Explore SLS for Yourself

By designing specifically for SLS, engineers can focus on performance, fit and function - not manufacturing limitations.

If you’d like to explore how SLS could help your team design smarter and faster, get in touch with our Applications Engineers or visit our demo suite to see the Fuse 1+ 30W in action.