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Direct Metal Laser Sintering
(DMLS) 3D Printing Services

End-Use Metal 3D Printing

Direct Metal Laser Sintering (DMLS) enables the production of robust and durable 3D printed metal prototypes and production runs. Metal 3D printing enables unparalleled manufacturing freedom, allowing them to create mechanically consistent end-use parts using a wide range of metals and alloys. 

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Metal 3D Printed part by Forge Labs

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. This additive manufacturing technique empowers businesses to unlock the potential of 3D printing for various applications, guaranteeing high strength and durability in the final products.


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.

EOS DMLS 3D printer

10" x 12" 

Max X/Y Build Volume

± 0.3

MM Part Tolerances


High Performance Materials

8 - 12 Day

Average Lead Time

Materials | Direct Metal Laser Sintering

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Stainless Steel

aluminum icon


titanium Icon


Stainless Steel 3D printed metal bracket

Stainless Steel 316L

Corrosion- Resistant Steel Alloy

316L Stainless Steel is produced using a powder bed technology 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


 89 HRB

Relative Density

 100 %

Material Datasheet
EOS 17-4 3D printed metal

Stainless Steel 17-4

High Strength & Hardness

Stainless steel 17-4 is widely used in engineering applications which require corrosion resistance and strength. Commonly used in applications that require high strength and durability, such as in aerospace, chemical processing, and in the manufacturing of mechanical components.


Tensile Strength

 886 MPa

Tensile Elongation

 20 %

Tensile Modulus

 200 GPa


 104 HRB

Relative Density

 100 %

Material Datasheet
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


 64 HRB

Relative Density

 100 %

Material Datasheet
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


 400 HV

Relative Density

 100 %

Material Datasheet
Direct Metal Laser Sintering

Material Surface Finishes

surface finish of a metal 3D printed part


Basic Finish

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


Surface Texture


Color & Appearance



Intricate details are usually well-represented and clear.


Minimal to no porosity

Turnaround Time

No additional time required
surface finish of a polished metal 3D printed part


Premium Finish

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


Surface Texture


Color & Appearance

Polished & Smooth


Details may be lost due to polishing



Turnaround Time

+3 business day
painting services for metal parts

Performance Paint

Premium Finish

Painting enables a highly durable automotive-grade coating of 3D printed parts. Parts are hand finished to a high quality and painted using high quality coating equipment.


Surface Texture

Matte to semi-gloss

Color & Appearance

Color matching available


Fine details may be lost if polishing is required.



Turnaround Time

+5 or more business days

Why Use Direct Metal Laser Sintering?

Metal 3D printing, also known as Direct Metal Laser Sintering, offers significant advantages over traditional manufacturing methods. It enables the creation of complex geometries and intricate shapes that are difficult to achieve with conventional techniques. The process reduces material waste, saves time and cost by eliminating the need for tooling or molds, and allows for the consolidation of multiple components into a single piece. Metal 3D printing supports a wide range of metallic materials, enabling the selection of ideal materials for specific applications. It facilitates rapid iteration and innovation, shortening the feedback loop between design, production, and testing. Additionally, metal 3D printing enables on-demand production, reducing the need for inventory storage and streamlining supply chain management. While it has some limitations, such as slower production speeds and the need for post-processing, metal 3D printing provides valuable benefits in terms of design flexibility, customization, efficiency, and innovation, revolutionizing manufacturing processes across industries.

3D Printed Metal Parts
Direct Metal Laser Sintering

Design Guidelines

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.  It 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.
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Maximum Build Volume

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

Our DMLS machines by EOS have a maximum building volume of: 400 mm x 400 mm x 400 mm (16 x 16 x 16) however the actual usable space varies by material and part geometry. 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.

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Best achievable tolerances - <100mm:  ±0.2mm, <200mm: ±0.3mm, <300mm: ±0.4mm, 300-400mm: ±0.4-0.5mm
Typically, the dimensional accuracy of DMLS parts is within +/- 0.3 mm however the accuracy of DMLS 3D printed parts can vary depending on several factors, including the specific machine and materials used, as well as the complexity of the part geometry. If you require tighter tolerances, please provide drawings along with your quote request.
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Layer Height

40 - 80 Microns
The layer height is the overall Z resolution of the part; we avoid stepping artifacts on important features of your models by orienting the part(s) along the Z plane or at a 20 degree angle on all sides. The standard layer height varies by material and is between 40 - 80 microns.
surface finish icon

Surface Finish

Uniform, Matte
Parts produced using DMLS provide a uniform finish with excellent mechanical properties. Metal 3D printed parts 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.
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.
Direct Metal Laser Sintering

Applications & Case Studies

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Medical Devices For Covid-19

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

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Fossil Reconstruction

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

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Metal 3d printing in Ontario

3D Printing In Ontario

A comprehensive guide to the 3D Printing Industry in Toronto, Ontario. How 3D printing has become an integral part of the factory of tomorrow.

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Frequently Asked Questions