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What is DMLS 3D Printing?

Direct Metal Laser Sintering (DMLS) is an advanced additive manufacturing technology that uses a high-powered laser to selectively melt metal powders layer by layer into fully dense and highly precise components. This process enables the production of complex geometries with high mechanical strength and is widely used in aerospace, automotive, medical, and industrial applications.

DMLS Materials

Aluminum Alloys

A lightweight aluminum alloy with good corrosion resistance, strength, and thermal conductivity. Commonly used in aerospace and automotive applications for structural components and electronic housings.

Ti6Al4V (Standard):

A titanium alloy known for its high strength-to-weight ratio, biocompatibility, and excellent corrosion resistance. Ideal for aerospace, medical implants, and automotive applications.

Inconel 718 (Standard & Fine):

A nickel-based superalloy offering exceptional resistance to high temperatures, oxidation, and mechanical stress. Used in aerospace, energy, and high-performance industrial applications.

Inconel 625 (Standard)

A corrosion-resistant in aggressive and high-temperature environments nickel alloy with excellent mechanical properties and fatigue resistance. Used in extreme environments like turbines, heat exchangers, and offshore piping.

316L Stainless Steel (Standard & Fine)

An austenitic stainless steel with excellent corrosion resistance in chemical and marine environments. Ideal for medical, food processing, and engineering applications.

17-4 PH Stainless Steel

A precipitation-hardened stainless steel with high strength and good corrosion resistance. Used in aerospace, medical, and industrial tooling applications.

Corrax

A corrosion-resistant tool steel with excellent dimensional stability and hardness. Ideal for injection mold tooling and high-wear applications.

Maraging Steel 1.2709

A high-strength steel with excellent hardness and toughness after heat treatment. Commonly used in aerospace, tooling, and high-performance engineering applications.

Cobalt-Chrome Alloy

A high-strength, biocompatible material widely used for dental, medical implants, and turbine components due to its wear and corrosion resistance.

CuCrZr (Copper-Chromium-Zirconium)

A high-conductivity copper alloy with improved mechanical strength and wear resistance. Ideal for heat exchangers, electrical contacts, and high-performance industrial applications.

DMLS Material Properties Compared

Material

Max. dimensions

Tensile Stress at break (MPa)

Tensile Modulus (GPa)

AlSi10Mg

500x280x340 mm

432-474

71-73

Ti6Al4V

280x280x340 mm

1045-1085

114

Inconel718

280x280x340 mm

930-1065

200

Inconel625

245x245x350 mm

880-940

133-178

Pure copper

250x250x290 mm

80-940

154

316L

280x280x350 mm

495-570

200

17-4PH

250x250x290 mm

1189-1267

151-162

Corrax

250x250x300 mm

1100

-

CoCr28Mo6

250x250x215 mm

100-1200

200

Maraging steel

280x280x350 mm

1122-1141

160

CuCrZr

280x280x350 mm

543

-

DMLS Surface Finishes

CNC machining

Enhances part precision with tight tolerances and smooth surfaces through post-processing on DMLS printed components.

Painting

Custom painting for visual appeal and added protection on DMLS parts, tailored to your design and color needs.

Heat Treatment

Improves mechanical properties and strength of metal parts through controlled heating and cooling processes.

Hot Isostatic Pressing - HIP

Hot Isostatic Pressing reduces internal porosity, increasing density and mechanical performance of 3D printed metal parts.

Surface Polishing

Produces smooth, glossy surfaces for improved aesthetics or functional requirements on metal parts.

Sandblasting

Uniform matte finish achieved by blasting fine abrasive particles, removing minor surface imperfections.

Anodization

Electrochemical process that enhances corrosion resistance and enables coloring of aluminum parts.

Quality Controls

Coordinate Measuring Machine - CMM

Involves using a Coordinate Measuring Machine to measure the geometrical characteristics of an object with high precision.

2D X-ray Inspection

Employs X-ray imaging to examine the internal structure of objects, identifying defects and ensuring structural integrity.

Computer Tomography scan - CT scan

Uses computed tomography to create detailed cross-sectional images of an object, allowing for in-depth inspection of its internal features.

Density Test

Measures the density of materials to ensure they meet specified standards and quality requirements.

Functional Testing

Leakage Test

Checks for leaks in sealed systems or components to ensure they are airtight and function properly.

Pressure Test

Subjects parts to pressure to verify their strength and integrity, ensuring they can withstand operational conditions.

Pros & Cons of DMLS 3D Printing

Pros

High mechanical strength and durability

Excellent material properties comparable or higher than those of casted metals

Ability to create complex geometries and fine details

Waste reduction compared to subtractive techniques

Allows for highly customized, complex and lightweight geometries

Shortens product development times by enabling the rapid creation of functional prototypes

Cons

High cost compared to other metal manufacturing methods

Post-processing is required to improve surface finish and stress-relief heat treatment often necessary

Limited build size depending on the printer capacity

Anisotropy in Mechanical Properties

Unfused Powder Removal

DMLS capabilities compared with other technologies

Capabilities

Max. Dimensions

Min. Feature Size

Min. wall thickness

Tolerance

Description

SLS

680x380x540 mm

0.8mm

0.7-1.3 mm 

±0.3% (±0.3mm)

Uses a laser to fuse powdered materials layer by layer, ideal for creating durable and complex parts without support structures,  widely employed in aerospace, automotive, and medical industries.

DMLS

500x280x340 mm

0.6-0.8 mm

0.22 mm

±0.25 (≤15mm);
±0.5 (>15mm)

Similar to SLS but uses metal powders, producing high-strength, intricate metal parts suitable for functional prototypes and end-use components in aerospace, medical, and automotive industries.

SLA

1350x750x500 mm

0.2-0.5 mm

1-3 mm

±0.2% (min. 0.2 mm)

Employs a UV laser to cure liquid resin into solid layers, ideal for creating highly detailed, smooth, and intricate parts. Widely used for detailed prototypes and intricate designs in jewelry and dental applications.

MJF

380x284x380 mm

0.5 mm

0.3-0.5 mm

±0.3% (±0.2 mm)

Utilizes multiple jets to apply fusing agents onto powder, which is then fused by heating elements. Delivers high-resolution, functional parts with fast production times, often used in aerospace, automotive, and consumer goods industries.

Polyjet

490x380x200 mm

1.2-2 mm

1 mm

±0.1%

Jetting liquid photopolymer resin and curing it layer by layer with UV light, enabling highly detailed, multi-material parts with diverse properties. Popular in prototyping and complex, color-rich models in medical modeling, consumer goods and electronics fields.

FDM

914x690x914 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 creating durable and functional prototypes. Commonly used in manufacturing, automotive, and consumer products.

DLP

510x280x350 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 and precise prints with high resolution. Commonly used in dental, jewelry, and high-detail prototype applications.

Large Scale

2500x2500x4000 mm

3 mm

-

±5 mm/mtl

Uses a digital light projector to cure liquid resin layer by layer, providing fast and precise prints with high resolution. Commonly used in dental, jewelry, and high-detail prototype applications.

DED

1200x800x600 mm

-

-

-

Uses an electron beam to melt and deposit metal powders or wire, ideal for repairing or adding features to metal parts in aerospace and manufacturing.

Bindet Jet

430x310x150 mm

-

-

±3% mm

Involves depositing a binder material onto a powder bed to form parts, which are then sintered. Useful for producing complex, cost-effective parts, often used automotive, aerospace, and consumer goods industries as well as jewerky.

FAQ about our DMLS 3D Printing service

What are the mechanical properties of DMLS 3D printed parts?

DMLS parts offer mechanical properties comparable or even higher to those of cast material, with higher relative density and lower porosity. They have high tensile strength, wear resistance, and thermal stability, depending on the selected material.

What are the dimensional tolerances of DMLS parts?

DMLS parts typically achieve tolerances of ±0.1 mm to ±0.3 mm, but accuracy can vary based on part geometry and post-processing requirements.

What are the design constraints for DMLS?

- Minimum Wall Thickness: Generally 0.5 mm to 1 mm, depending on the material.
- Support Structures: Required for overhangs and complex geometries but can be minimized with optimized designs.
- Post-Processing: Heat treatment, machining, and surface finishing may be necessary to achieve final specifications.

How does DMLS compare to other 3D printing technologies?

DMLS produces fully dense, high-strength metal parts, unlike polymer-based additive technologies. Compared to traditional machining, it allows for the creation of intricate geometries without the need for extensive tooling.

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