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Direct Metal Laser Sintering (DMLS) 3D Printing

Complex Functional 3D Printed Metal Parts

Unlock total manufacturing freedom and 3D Print end use parts in mechanically consistent metals and alloys.

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Direct Metal Laser Sintering (DMLS) 3D Printing

Complex Functional 3D Printed Metal Parts

Unlock total manufacturing freedom and 3D Print end use parts in mechanically consistent metals and alloys.

Get an Instant Quote

What is Direct Metal Laser Sintering (DMLS)?

Direct Metal Laser Sintering (DMLS) is an additive manufacturing method that provides the freedom to manufacture complex functional assemblies directly in metal.  Parts are created by selectively sintering metal powder layer-by-layer using a high powered laser with little to no need for machining. This allows for the production of complex parts not possible by traditional manufacturing methods.

Manufacturing metal parts using Direct Metal laser Sintering is ideal for rapidly producing precise, complex metal parts with lattice structures and hollow cavities. This additive manufacturing technology allows designers the freedom to create lightweight, highly functional parts for a variety of end-use applications. This makes the technology popular in high performance applications such as automotive and aerospace manufacturing where designers can take advantage of the freedom of DMLS to produce lighter and more complex parts without compromising part strength.

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What is Direct Metal Laser Sintering (DMLS)?

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Direct Metal Laser Sintering (DMLS) is an additive manufacturing method that provides the freedom to manufacture complex functional assemblies directly in metal.  Parts are created by selectively sintering metal powder layer-by-layer using a high powered laser with little to no need for machining. This allows for the production of complex parts not possible by traditional manufacturing methods.

Metal parts produced by DMLS are ideal for producing highly precise, complex metal parts with lattice structures and hollow cavities. This additive manufacturing technology allows designers the freedom to create lightweight, highly functional parts for a variety of end-use applications.

10" x 12" 

Max X/Y Build Volume

± 0.3

MM Part Tolerances

3

High Performance Materials

8-10 Day

Average Lead Time

10" x 12"

Max X/Y Build Volume

± 0.3

MM Part Tolerances

3

High Performance Materials

8-10 Day

Average Lead Time

Materials| Selective Laser Sintering

 
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Stainless Steel

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Aluminum

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Titanium

 
Stainless Steel 3D printed metal bracket

Stainless Steel 316L

Corrosion-Resistant Steel Alloy

316L Stainless Steel is produced using a powder bed tehnology known as direct metal laser sintering. 316L stainless steel is a widely used high-strength, high-hardness metal with excellent corrosion resistance ideal for automotive, industrial & aerospace applications.

Tensile Strength

 640 MPa

Tensile Elongation

 40 %

Tensile Modulus

 185 GPa

Hardness

 89 HRB

Relative Density

 100 %

Material Data Sheet
Aluminum 3D printed part

Aluminum AlSi10Mg

Lightweight Alloy

Aluminum AlSi10Mg is produced using a powder bed 3D Printing technology known as direct metal laser sintering. AlSi10Mg is widely used for light weight, thin wall parts for aerospace and automotive applications. AlSi10Mg offers fantastic machinability as well as good thermal and strength properties.

Tensile Strength

 379 MPa

Tensile Elongation

 10 %

Tensile Modulus

 68 GPa

Hardness

 64 HRB

Relative Density

 100 %

Material Data Sheet
Titanium 3D printed seat buckle

Titanium Ti64

Corrosion Resistant Alloy 

Titanium Ti64 is produced using powder bed 3D Printing technology known as direct metal laser sintering. Ti64 is widely used for high performance parts that require corrosion resistance and low specific weight and/or biocompatibility. 

Tensile Strength

 1150 MPa

Tensile Elongation

 11 %

Tensile Modulus

 68 GPa

Hardness

 400 HV

Relative Density

 100 %

Material Data Sheet

Materials| Selective Laser Sintering

Image

Stainless Steel

Image

Aluminum

Image

Titanium

Image

Stainless Steel 316L

Corrosion-Resistant Steel Alloy

316L Stainless Steel is produced using a powder bed tehnology known as direct metal laser sintering. 316L stainless steel is a widely used high-strength, high-hardness metal with excellent corrosion resistance ideal for automotive, industrial & aerospace applications.

Tensile Strength

 640 MPa

Tensile Elongation

 40 %

Tensile Modulus

 185 GPa

Hardness

 89 HRB

Relative Density

 100 %

Material Data Sheet
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Aluminum AlSi10Mg

Lightweight Alloy

Aluminum AlSi10Mg is produced using a powder bed 3D Printing technology known as direct metal laser sintering. AlSi10Mg is widely used for light weight, thin wall parts for aerospace and automotive applications. AlSi10Mg offers fantastic machinability as well as good thermal and strength properties.

Tensile Strength

 379 MPa

Tensile Elongation

 10 %

Tensile Modulus

 68 GPa

Hardness

 64 HRB

Relative Density

 100 %

Material Data Sheet
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Titanium Ti64

Corrosion Resistant Alloy 

Titanium Ti64 is produced using powder bed 3D Printing technology known as direct metal laser sintering. Ti64 is widely used for high performance parts that require corrosion resistance and low specific weight and/or biocompatibility. 

Tensile Strength

 1150 MPa

Tensile Elongation

 11 %

Tensile Modulus

 68 GPa

Hardness

 400 HV

Relative Density

 100 %

Material Data Sheet

Material Surface Finishes | Direct Metal Laser Sintering

Standard

Support structures removed and part is shot-peened to a uniform finish. Critical features are hand finished. Surface roughness between 200-400 Ra.

Custom

Critical features hand finished to a high aesthetic quality. Tight tolerance features machined to specification.

Material Surface Finishes | Direct Metal Laser Sintering

Standard 

Support structures removed and part is shot-peened to a uniform finish. Critical features are hand finished. Surface roughness between 200-400 Ra.

Custom

Critical features hand finished to a high aesthetic quality. Tight tolerance features machined to specification.

Critical features hand finishes and model is finished to a high aesthetic quality. High tolerance features machined to specification.

Critical features hand finishes and model is finished to a high aesthetic quality. High tolerance features machined to specification.

Critical features hand finishes and model is finished to a high aesthetic quality. High tolerance features machined to specification.

 

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Start a new DMLS Quote

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Design Guidelines | Direct Metal Laser Sintering

Direct Metal Laser Sintering (DMLS) is an additive manufacturing process that uses a bed of metal powder, fused together via a high powered laser. The laser fuses layers together by selectively scanning and hardening fine particles of metal powder to create a solid structure. After each cross section is sintered, the machine deposits another 40 um layer metal powder and the process repeats itself until the build is complete.  

Direct Metal Laser Sintering is a complex manufacturing process that requires significant amount of post processing to remove the physical supports. These design guidelines covers specific design parameters, which will need to be followed to prevent build failures from occurring. 

Optimizing your designs for Direct Metal laser Sintering will help keep manufacturing costs down. Price is primarily based upon the X, Y, & Z extents of your part with the biggest cost factor being how tall the part sits in the build. Small, dense or parts that nest low in the z-axis will be priced the most competitively in this technology. Wall thickness has a modest effect on the cost of the part, so it is important to avoid overly bulky or dense features.

Our DMLS machines have a building volume of: 400 x 400 x 400 mm (15.8 x 15.8 x 15.8 in) and a laser diameter of 100 um.

The throughput of Direct Metal Laser Sintering is limited, as parts can only be nested in the X & Y planes in the build chamber. This limits the amount of parts that can be built in a single run, making it more ideal for low volume manufacturing of small highly complex parts. Parts produced using DMLS are fully dense and provide a uniform finish with excellent mechanical properties, making it a suitable substitute to machining. Additional post-processing options are available to improve the surface finish or machine critical features to specification.

  • Minimum Wall Thickness

    0.8 mm

  • Engraved Details

    Thickness & depth of at least 0.8 mm

  • Embossed Details

    Thickness & depth of at least 0.7 mm

  • Clearance

    0.5 mm

  • Minimum Hole Size

    1.5 mm or 3 mm for internal chanels

  • Layer Height

    40 μm

  • Maximum Build Size

    400 x 400 x 400 mm (15.8 x 15.8 x 15.8 in)

  • Tolerances

    ±0.3%, with a lower limit of ±0.3 mm.

  • Surface Finish

    Parts are shot peened to a surface roughness of 400 Ra

  • Warping & Deformities

    Avoid large flat planes which are likely to cause warping.

Download Full Design Guidelines
Design Guidelines | Direct Metal Laser Sintering

Direct Metal Laser Sintering (DMLS) is an additive manufacturing process that uses a bed of metal powder, fused together via a high powered laser. The laser fuses layers together by selectively scanning and hardening fine particles of metal powder to create a solid structure. After each cross section is sintered, the machine deposits another 40 um layer metal powder and the process repeats itself until the build is complete.  

Direct Metal Laser Sintering is a complex manufacturing process that requires significant amount of post processing to remove the physical supports. These design guidelines covers specific design parameters, which will need to be followed to prevent build failures from occurring. 

Optimizing your designs for Direct Metal laser Sintering will help keep manufacturing costs down. Price is primarily based upon the X, Y, & Z extents of your part with the biggest cost factor being how tall the part sits in the build. Small, dense or parts that nest low in the z-axis will be priced the most competitively in this technology. Wall thickness has a modest effect on the cost of the part, so it is important to avoid overly bulky or dense features.

Our DMLS machines have a building volume of: 400 x 400 x 400 mm (15.8 x 15.8 x 15.8 in) and a laser diameter of 100 um.

The throughput of Direct Metal Laser Sintering is limited, as parts can only be nested in the X & Y planes in the build chamber. This limits the amount of parts that can be built in a single run, making it more ideal for low volume manufacturing of small highly complex parts. Parts produced using DMLS are fully dense and provide a uniform finish with excellent mechanical properties, making it a suitable substitute to machining. Additional post-processing options are available to improve the surface finish or machine critical features to specification.

  • Minimum Wall Thickness

    0.8 mm

  • Engraved Details

    Thickness & depth of at least 0.8 mm

  • Embossed Details

    Thickness & depth of at least 0.7 mm

  • Clearance

    0.5 mm

  • Minimum Hole Size

    1.5 mm or 3 mm for internal chanels

  • Layer Height

    60 μm- 100 μm

  • Maximum Build Size

    700 mm x 380 mm x 580 mm (27.6 x 15 x 22.9 in.)

  • Tolerances

    ±0.3%, with a lower limit of ±0.3 mm.

  • Surface Finish

    Parts are shot peened to a surface roughness of 400 Ra

  • Warping & Deformities

    Avoid large flat planes which are likely to cause warping.

Download Full Design Guidelines
Why Use Direct Metal Laser Sintering?
  • Functional End Use Parts

    Strong, fully dense functional parts suitable for aerospace, automotive and other demanding applications

  • Simplified Assemblies

    Print complex assemblies in a single run that offer the same mechanical performance as machined parts

  • No Cost for Complexity

    Save time and money machining complex parts with the freedom of metal 3D printing

  • Lightweight

    Utilize topology optimization to construct strong, high performance 3D printed parts that save weight

Industry Advantages| Direct Metal Laser Sintering
  • Functional End Use Parts

    Strong, fully dense functional parts suitable for aerospace, automotive and other demanding applications

  • Simplified Assemblies

    Print complex assemblies as a single part to reduce labor.

  • No Cost for Complexity

    Save time and money machining complex parts with the freedom of metal 3D printing

  • Lightweight

    Utilize topology optimization to construct strong, high performance 3D printed parts that save weight

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Aerospace

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Automotive

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Healthcare

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Film & TV

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Industrial Design

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Architecture

Case Studies | Direct Metal Laser Sintering

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COVID relief efforts supported by Forge Lab's 3D Printing services. See the technologies & materials we offer for medical-end use applications. 

Read Case Study ->

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How Forge Labs used a combination of 3D scanning & SLS 3D printing to reconstruct a 12,500 year old fossilized skeleton of bison occidentalis.

Read Case Study ->

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A comprehensive guide to metal 3D printing in Toronto, Ontario. How Direct Metal Laser Sintering has become an integral part of automotive manufacturing.

Read Case Study ->

Case Studies | Direct Metal Laser Sintering

Image

COVID relief efforts supported by Forge Lab's 3D Printing services. See the technologies & materials we offer for medical-end use applications. 

Read Case Study ->

Image

How Forge Labs used a combination of 3D scanning & SLS 3D printing to reconstruct a 12,500 year old fossilized skeleton of bison occidentalis.

Read Case Study ->

Image

A comprehensive guide to metal 3D printing in Toronto, Ontario. How Direct Metal Laser Sintering has become an integral part of automotive manufacturing.

Read Case Study ->