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56. How do you make SLS metal parts and tooling inserts?

An SLS metal part is made following the below approaches: (A) build a "green" part on the machine by fusing powdered steel particles with a polymer binder material; (B) in a furnace cycle the binder is burned away, the steel particles are lightly sintered and molten bronze wicks into the resulting pores forming a fully dense steel/bronze object.

Most other metal parts are created by casting in temporary tooling created from a pattern master made on a rapid prototyping apparatus, or by machining objects from a block of bar stock.