Abstract: A process of fabricating aerospace parts using selective laser sintering is provided, wherein the process generally comprises the steps of preparing a powder nylon material, loading the powder nylon material into a laser sintering machine, warming up the powder nylon material according to build warm-up parameters, building the part according to build parameters and part parameters, and cooling down the part according to build cool-down parameters. As a result, parts are produced that are directly used in aerospace structures, which meet the stringent performance requirements of aerospace applications, rather than as rapid prototypes as with conventional selective laser sintering processes. Additionally, specific designs for aerospace parts such as ducts, panels, and shrouds are provided that are produced by the selective laser sintering process.