Direct Metal Laser Sintering (DMLS)
High-precision metal 3D printing for prototypes and production parts. Fully dense metal components with exceptional mechanical properties.
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High-Quality Metal Parts Without Tooling
Direct Metal Laser Sintering (DMLS) is an additive manufacturing technology that uses a high-powered laser to selectively fuse metal powder particles layer by layer, building fully dense metal parts directly from CAD data.
Unlike traditional manufacturing, DMLS enables complex geometries including internal channels, lattice structures, and consolidated assemblies that would be impossible or prohibitively expensive to machine. Parts are built with 99.5%+ density, delivering mechanical properties comparable to wrought metal.
With no tooling or setup costs, DMLS is an economical choice for prototypes and low-to-mid volume production. The layer-by-layer process also enables multi-part assemblies to be printed as single components, reducing weight and eliminating potential failure points.
DMLS Capabilities
| Build Size | 250 x 250 x 250mm (10" x 10" x 10") |
| General Tolerances | ±0.13mm for the first 25mm, plus ±0.05mm per 25mm thereafter |
| Layer Height | 30-40 microns (0.0012-0.0016") depending on material |
| Surface Roughness | Ra 4-10 µm (150-400 µin), depending on orientation and material |
| Part Density | 99.5%+ (fully dense) |
| Minimum Wall Thickness | 0.5mm (0.020") |
Tolerances may vary based on geometry, wall thickness, and build orientation. Parts with broad flat surfaces may be prone to warping.
How DMLS Works
The DMLS process begins with a thin layer of metal powder spread across a build platform. A high-powered laser then traces the cross-section of the part, selectively melting and fusing the powder particles together.
The build platform lowers by one layer thickness (typically 30-40 microns), a new layer of powder is spread, and the laser traces the next cross-section. This process repeats thousands of times until the complete part is formed.
After printing, parts are removed from the build plate, support structures are removed, and post-processing such as heat treatment or surface finishing is applied as needed.
DMLS Materials
High-performance metal alloys for demanding applications.
Aluminum AlSi10Mg
Lightweight aluminum alloy with excellent thermal conductivity. Ideal alternative to machining for complex geometries.
Aerospace brackets, heat exchangers, lightweight structural parts
Stainless Steel 17-4 PH
Precipitation-hardening stainless steel with high strength and good corrosion resistance. Heat treatable to 40 HRC.
Aerospace components, medical devices, industrial tooling
Stainless Steel 316L
Austenitic stainless steel with excellent corrosion resistance and biocompatibility. Meets ASTM F138 requirements.
Medical implants, marine hardware, chemical processing equipment
Additional materials including Titanium Ti6Al4V, Inconel 625/718, and Tool Steel available upon request.
Available Finishes
Standard (Media Blasted)
Support structures removed and surfaces media blasted to provide a uniform matte finish.
Machined Features
Critical features CNC machined for tighter tolerances and improved surface finish.
Polished
Surfaces polished to achieve smoother finish for aesthetic or functional requirements.
Heat Treated
Thermal processing to optimize mechanical properties and relieve residual stresses.
Best Applications for DMLS
Rapid Tooling
Strong yet lightweight parts ideal for fixtures, jigs, and manufacturing aids with complex geometries.
Rapid Prototyping
Affordable and fast metal prototypes for proof-of-concept models and functional late-stage testing.
End-Use Production
Fully dense parts with excellent mechanical properties suitable for demanding production applications.
Benefits of DMLS 3D Printing
No Tooling Required
Go directly from CAD to metal parts without expensive molds or tooling setup costs.
Fully Dense Parts
99.5%+ density produces parts with mechanical properties comparable to wrought metal.
Complex Geometries
Create internal channels, lattice structures, and consolidated assemblies impossible with machining.
All-In-One Assemblies
Combine multiple components into single printed parts, reducing weight and assembly complexity.
Design Freedom
Topology optimization, organic shapes, and internal supports that traditional manufacturing cannot achieve.
Rapid Turnaround
Metal parts delivered in days rather than weeks typical of traditional manufacturing.
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Endless Options
Choose from multiple metal alloys with various finishes, tolerances, and post-processing options for your specific requirements.
Easy to Use
Get metal parts delivered to your door without the hassle of sourcing, project management, or logistics coordination.
Certified Quality
ISO 9001:2015, ISO 13485, and AS9100D certified partners ensure consistent, high-quality results on every order.
Start Your DMLS 3D Printing Project
Upload your CAD files and get instant pricing for fully dense aluminum and stainless steel parts with complex geometries.