AlSi10Mg (Standard & Fine)
A lightweight aluminium alloy with good corrosion resistance, high mechanical strength, and excellent thermal conductivity. Commonly used in aerospace, automotive, mechanical engineering, and automation applications.
DMLS 3D Printing service
- Wide range of metals and alloys: aluminium, titanium, stainless steels, nickel alloys, copper and more
- ISO 9001:2015, IATF, ISO 9100 certifications
Direct Metal Laser Sintering (DMLS) is an advanced Additive Manufacturing technology
It uses a high-power laser to selectively melt metal powders, layer by layer, until solid, precise parts are obtained.
This process enables complex geometries with excellent mechanical properties, and is widely used in aerospace, medical, automotive and industrial applications.
DMLS 3D printing use cases
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High-performance functional components
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Complex geometries
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Lightweight components
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Heat exchangers and internal channels
-
Integrating multiple functions into a single component
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Replacement parts for obsolete components
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Small production runs of metal components
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Tooling and inserts with conformal cooling
Materials for DMLS 3D printing
Aluminium alloys
Titanium alloys
Ti6Al4V (Standard)
A biocompatible, high-strength titanium alloy used in medical, aerospace, and defence applications.
Nickel alloys
Inconel 718 (Standard & Fine)
A nickel-based superalloy designed for high temperatures and mechanical stress, suitable for extreme environments.
Inconel 625 (Standard)
A nickel alloy with excellent resistance to corrosion and fatigue, ideal for turbines and heat exchangers.
Steel
316L Stainless Steel (Standard & Fine)
Stainless steel for chemical and marine environments, used in medical and food applications.
17-4 PH Stainless Steel
High-strength stainless steel with good corrosion resistance, used in tooling and aerospace applications.
Corrax
Tool steel with high dimensional stability and hardness.
Maraging Steel 1.2709
A special steel with excellent properties after heat treatment, used in high-performance engineering applications.
Chrome alloys
Cobalt Chrome Alloy
A biocompatible, high-strength alloy for dental and medical applications.
Copper alloys
CuCrZr (Copper Chromium-Zirconium)
A high-conductivity copper alloy for heat exchangers and electrical contacts.
Our team of experts is at your disposal
Our engineers support you in material selection, optimising the part for metal 3D printing, and defining the required post-processes and inspections.
DMLS finishing options
Painting
Aesthetic finish and part protection with custom painting on request.
Final result:
- Uniform aesthetic finish
- Customisable colour
- Greater surface protection
Anodising
Anodising for corrosion protection and colouring of 3D-printed aluminium parts.
Final result:
- Greater corrosion resistance
- More wear-resistant surface
- Customisable aesthetic finish
Quality control and testing for DMLS
Coordinate measuring - CMM
Measures part geometries with coordinate measuring machines to check tolerances and drawing compliance.
2D X-ray inspection
Uses X-ray imaging to detect internal defects, inclusions and discontinuities without damaging the part.
Tomography
Reconstructs the internal volume to analyse porosity, channels and inaccessible geometries.
Density test
Measures material density to check that the printing process meets the required quality standards.
Comparison with other technologies
| Technology | Max. size | Min. detail size | Min. wall thickness | Tolerance | Description |
|---|---|---|---|---|---|
| DMLS | 500×280×340 mm | 0.6-0.8 mm | 0.22 mm | ±0.25 (≤15mm); ±0.5 (>15mm) | Similar to Selective Laser Sintering (SLS), but uses metal powders to produce high-strength, intricate metal parts, suitable for functional prototypes and end-use components in aerospace, medical and automotive. |
| SLS Plastic | 680×380×540 mm | 0.8 mm | 0.7-1.3 mm | ±0.3% (±0.3mm) | Uses a laser to fuse powdered materials layer by layer, ideal for durable, complex parts without support structures. Widely used in aerospace, automotive and medical. |
| SLA Plastic | 1350×750×500 mm | 0.2-0.5 mm | 1-3 mm | ±0.2% (min. 0.2 mm) | Uses a UV laser to cure liquid resin into solid layers, ideal for highly detailed, smooth, intricate parts. Widely used for detailed prototypes and complex designs in jewellery and dentistry. |
| MJF Plastic | 380×284×380 mm | 0.5 mm | 0.3-0.5 mm | ±0.3% (±0.2 mm) | Uses multiple jets to apply fusing agents onto powder, which is then fused by heating elements. Delivers high-resolution functional parts with short lead times, often used in aerospace, automotive and consumer goods. |
| Polyjet Plastic | 490×380×200 mm | 1.2-2 mm | 1 mm | ±0.1% | Jets liquid photopolymer resin and cures it layer by layer with UV light, enabling highly detailed, multi-material parts with different properties. Popular for prototyping and colour-rich complex models in medical modelling, consumer goods and electronics. |
| FDM Plastic | 914×690×914 mm | 1.2-1.5 mm | 1.5 mm | ±0.5% (±0.5 mm) | Uses a heated nozzle to extrude thermoplastic filament layer by layer, ideal for durable functional prototypes. Commonly used in manufacturing, automotive and consumer products. |
| DLP Plastic | 510×280×350 mm | 0.5 mm | 1 mm | ±0.30 mm < 100mm; ±0.3% > 100 mm | Uses a digital light projector to cure liquid resin layer by layer, providing fast, precise, high-resolution prints. Commonly used in dentistry, jewellery and high-definition prototypes. |
| Large Scale Plastic | 2500×2500×4000 mm | 3 mm | — | ±5 mm/m | Refers to 3D printing technologies designed to create large objects or structures, such as industrial machine parts or architectural models, with an emphasis on size and structural integrity. |
| DED | 1200×800×600 mm | — | — | — | Uses an energy beam to melt and deposit metal powders or wires, ideal for repairing or adding features to metal parts in aerospace and manufacturing. |
| Binder Jet | 430×310×150 mm | — | — | ±3% | Deposits a binding agent onto a powder bed to form parts, which are then sintered. Useful for producing complex, cost-effective parts, often used in automotive, aerospace, consumer goods and jewellery. |
Technology
DMLS
- Max. size
- 500×280×340 mm
- Min. detail size
- 0.6-0.8 mm
- Min. wall thickness
- 0.22 mm
- Tolerance
- ±0.25 (≤15mm); ±0.5 (>15mm)
Description
Similar to Selective Laser Sintering (SLS), but uses metal powders to produce high-strength, intricate metal parts, suitable for functional prototypes and end-use components in aerospace, medical and automotive.
Technology
SLS
Plastic- Max. size
- 680×380×540 mm
- Min. detail size
- 0.8 mm
- Min. wall thickness
- 0.7-1.3 mm
- Tolerance
- ±0.3% (±0.3mm)
Description
Uses a laser to fuse powdered materials layer by layer, ideal for durable, complex parts without support structures. Widely used in aerospace, automotive and medical.
Technology
SLA
Plastic- Max. size
- 1350×750×500 mm
- Min. detail size
- 0.2-0.5 mm
- Min. wall thickness
- 1-3 mm
- Tolerance
- ±0.2% (min. 0.2 mm)
Description
Uses a UV laser to cure liquid resin into solid layers, ideal for highly detailed, smooth, intricate parts. Widely used for detailed prototypes and complex designs in jewellery and dentistry.
Technology
MJF
Plastic- Max. size
- 380×284×380 mm
- Min. detail size
- 0.5 mm
- Min. wall thickness
- 0.3-0.5 mm
- Tolerance
- ±0.3% (±0.2 mm)
Description
Uses multiple jets to apply fusing agents onto powder, which is then fused by heating elements. Delivers high-resolution functional parts with short lead times, often used in aerospace, automotive and consumer goods.
Technology
Polyjet
Plastic- Max. size
- 490×380×200 mm
- Min. detail size
- 1.2-2 mm
- Min. wall thickness
- 1 mm
- Tolerance
- ±0.1%
Description
Jets liquid photopolymer resin and cures it layer by layer with UV light, enabling highly detailed, multi-material parts with different properties. Popular for prototyping and colour-rich complex models in medical modelling, consumer goods and electronics.
Technology
FDM
Plastic- Max. size
- 914×690×914 mm
- Min. detail size
- 1.2-1.5 mm
- Min. wall thickness
- 1.5 mm
- Tolerance
- ±0.5% (±0.5 mm)
Description
Uses a heated nozzle to extrude thermoplastic filament layer by layer, ideal for durable functional prototypes. Commonly used in manufacturing, automotive and consumer products.
Technology
DLP
Plastic- Max. size
- 510×280×350 mm
- Min. detail size
- 0.5 mm
- Min. wall thickness
- 1 mm
- Tolerance
- ±0.30 mm < 100mm; ±0.3% > 100 mm
Description
Uses a digital light projector to cure liquid resin layer by layer, providing fast, precise, high-resolution prints. Commonly used in dentistry, jewellery and high-definition prototypes.
Technology
Large Scale
Plastic- Max. size
- 2500×2500×4000 mm
- Min. detail size
- 3 mm
- Min. wall thickness
- —
- Tolerance
- ±5 mm/m
Description
Refers to 3D printing technologies designed to create large objects or structures, such as industrial machine parts or architectural models, with an emphasis on size and structural integrity.
Technology
DED
- Max. size
- 1200×800×600 mm
- Min. detail size
- —
- Min. wall thickness
- —
- Tolerance
- —
Description
Uses an energy beam to melt and deposit metal powders or wires, ideal for repairing or adding features to metal parts in aerospace and manufacturing.
Technology
Binder Jet
- Max. size
- 430×310×150 mm
- Min. detail size
- —
- Min. wall thickness
- —
- Tolerance
- ±3%
Description
Deposits a binding agent onto a powder bed to form parts, which are then sintered. Useful for producing complex, cost-effective parts, often used in automotive, aerospace, consumer goods and jewellery.
DMLS technology pros and cons
Advantages
- Access a selected network of technologies, materials and manufacturing partners to make custom parts, from prototype to series.
- Properties comparable to (or better than) cast metals, including reduced porosity.
- Ability to produce complex, lightweight geometries.
- Reduced waste.
- Fast functional prototyping and pre-series with a path to serial production.
- Shorter product development times through rapid functional prototypes.
Points to consider
- Higher cost compared with other processes.
- Post-processing required (heat treatments, finishing).
- Limited build volume for the selected materials.
- Anisotropic mechanical properties.
- Removal of unsintered powder from closed areas of the geometry.
DMLS 3D printing FAQ
What metals can be used with DMLS 3D printing?
DMLS (Direct Metal Laser Sintering) is a metal 3D printing technology that produces functional components directly from metal powders. MadeInAdd offers aluminium alloys, stainless steels, Inconel, copper, and titanium, selected according to project requirements. Material selection depends on factors such as mechanical strength, weight, operating temperature, corrosion resistance, and thermal conductivity. MadeInAdd can support the selection of the alloy best suited to the component’s functional and production requirements.
What accuracy and tolerances can be achieved with DMLS 3D printing?
The accuracy of DMLS metal 3D printing depends on geometry, dimensions, print orientation, and post-processing. Indicative minimum feature sizes are around 0.6–0.8 mm, with wall thicknesses down to approximately 0.22 mm. Reference tolerances are ±0.25 mm for dimensions up to 15 mm and ±0.5 mm above 15 mm. For fits, holes, or functional surfaces requiring tighter tolerances, DMLS can be combined with CNC machining and dedicated post-processing.
What are the advantages of DMLS compared with traditional manufacturing processes?
DMLS offers greater design freedom for complex metal components, enabling internal channels, lightweight structures, and geometries optimised for fluid flow and heat exchange. The technology can also integrate multiple functions into a single component and supports topology optimisation and Design for Additive Manufacturing (DfAM). The advantages over traditional manufacturing technologies depend on geometry, material, quantity, and project requirements.
When is DMLS the right choice?
DMLS is suitable for high-performance functional metal components, particularly when the geometry and part requirements make additive manufacturing advantageous. It is especially well suited to complex internal channels, lightweight structures, optimised geometries, and components integrating multiple functions. Typical applications include aerospace, automotive, medical, and machinery. MadeInAdd can support projects with DfAM, topology optimisation, CAD/CAE analysis, post-processing, and validation.
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