Direct Metal Laser Sintering (DMLS) is an industrial metal 3D printing process that creates fully functional metal prototypes and production parts in 7 days or less. Various metals are used to produce final parts suitable for end-use applications.

Metal 3D printing technology is typically applied for:

  • Prototyping with production-grade materials
  • Creating complex geometries
  • Manufacturing functional, end-use parts
  • Reducing the number of metal components in an assembly

Metal 3D Printing Capabilities

Our fundamental guidelines for metal 3D printing outline key design considerations to optimize manufacturability, improve surface quality, and minimize production time.

US Metric
Normal Resolution 9.6 in. x 9.6 in. x 13.0 in. 245mm x 245mm x 330mm
Normal Resolution (X Line*) 31.5 in. x 15.7 in. x 19.7 in. 400mm x 800mm x 500mm
High Resolution 3.5 in. x 3.5 in. x 2.7 in.
Al: 3.8 in. x 3.8 in. x 3.7 in.		 88mm x 88mm x 70mm
Al: 98mm x 98mm x 94mm
US Metric
Normal Resolution 0.0012 in. 30 microns
Normal Resolution (X Line*) Inconel: 0.00236 in.
Aluminum: 0.00157 in.		 Inconel: 60 microns
Aluminum: 40 microns
High Resolution 0.00079 in. 20 microns
US Metric
Normal Resolution 0.015 in
(0.030 in. for Aluminum)		 0.381mm
(0.762mm for Aluminum)
Normal Resolution (X Line*) 0.015 in.
(0.030 in. for Aluminum)		 0.381mm
(0.762mm for Aluminum)
High Resolution 0.006 in.
Aluminum: 0.015 in.		 0.153mm
Aluminum: 0.381mm

Metal 3D Printing Tolerances

For well-designed parts, typical tolerances in the X/Y dimension are ±0.003 in. (0.075mm) for the first inch, plus 0.1% of the nominal length (0.001mm/mm). In the Z dimension, tolerances of ±0.006 in. for the first inch, plus 0.1% of the nominal length, can generally be achieved. Keep in mind that tolerances may vary based on part geometry.

Currently, Inconel 718 and Aluminum are the only materials available for our large-format X Line machine.

Finishing Option Description
Standard Support structures are removed and layer lines are visible.
Brushed Indicated surfaces will be directionally sanded to desired grit level.
Satin Indicated surfaces will be sanded to desired grit level, grit blasted and then bead blasted.
Polished Indicated surfaces will be sanded to desired grit level. Surfaces will be somewhat reflective and bright, but some sanding lines or marks may still be visible.

Compare Material Properties

Materials Resolution Condition Ultimate Tensile Strength (ksi) Yield Stress (ksi) Elongation (%) Hardness
Stainless Steel
(17-4 PH)		 20 μm Solution & Aged (H900) 199 178 10 42 HRC
30 μm Solution & Aged (H900) 198 179 13 42 HRC
Stainless Steel
(316L)		 20 μm Stress Relieved 82 56 78 90 HRB
30 μm Stress Relieved 85 55 75 88 HRB
Aluminum
(AlSi10Mg)		 20 μm Stress Relieved 39 26 15 42 HRB
30 μm Stress Relieved 50 33 8 59 HRB
40 μm Stress Relieved 43 27 10 50 HRB
Cobalt Chrome
(Co28Cr6Mo)		 20 μm As Built 182 112 17 39 HRC
30 μm As Built 176 119 14 38 HRC
Inconel 718 20 μm Stress Relieved 143 98 36 33 HRC
30 μm Stress Relieved 144 91 39 30 HRC
30 μm Solution & Aged per AMS 5663 208 175 18 46 HRC
60 μm Stress Relieved 139 83 40 27 HRC
60 μm Solution & Aged per AMS 5663 201 174 19 45 HRC
Titanium
(Ti6Al4V)		 20 μm Stress Relieved 153 138 15 35 HRC
30 μm Stress Relieved 144 124 18 33 HRC
Materials Resolution Condition Ultimate Tensile Strength (MPa) Yield Stress (MPa) Elongation (%) Hardness
Stainless Steel (17-4 PH) 20 μm Solution & Aged (H900) 1,372 1,227 10 42 HRC
30 μm Solution & Aged (H900) 1,365 1,234 13 42 HRC
Stainless Steel (316L) 20 μm Stress Relieved 565 386 78 90 HRB
30 μm Stress Relieved 586 379 75 88 HRB
Aluminum (AlSi10Mg) 20 μm Stress Relieved 268 180 15 46 HRB
30 μm Stress Relieved 345 228 8 59 HRB
40 μm Stress Relieved 296 186 10 50 HRB
Cobalt Chrome (Co28Cr6Mo) 20 μm As Built 1,255 772 17 39 HRC
30 μm As Built 1,213 820 14 38 HRC
Copper (CuNi2SiCr) 20 μm Precipitation Hardened 496 434 23 87 HRB
Inconel 718 20 μm Stress Relieved 986 676 36 33 HRC
30 μm Stress Relieved 993 627 39 30 HRC
30 μm Solution & Aged per AMS 5663 1,434 1,207 18 46 HRC
60 μm Stress Relieved 958 572 40 27 HRC
60 μm Solution & Aged per AMS 5663 1,386 1,200 19 45 HRC
Titanium (Ti6Al4V) 20 μm Stress Relieved 1,055 951 15 35 HRC
30 μm Stress Relieved 993 855 18 33 HRC

20 μm = high resolution (HR)

30, 40, and 60 μm = normal resolution (NR)

These values are approximate and may vary based on several factors, such as machine settings and process parameters. Therefore, the information provided is not binding and should not be considered certified. For critical performance requirements, independent testing of the additive materials or final components is recommended.

Metal 3D Printing Material Options

Here is a list of the metal alloys we offer for 3D printing. Different heat treatment options are available based on the material.

Stainless Steel (17-4 PH)

Stainless Steel 17-4 PH is a precipitation-hardened alloy recognized for its excellent hardness and corrosion resistance. When opting for stainless steel, 17-4 PH is a great choice due to its significantly higher tensile and yield strength compared to other grades, although it has lower elongation at break than 316L. Parts made from 17-4 PH undergo vacuum solution heat treatment followed by H900 aging for enhanced properties.

Key Advantages

  • Fully heat-treated for maximum hardness and strength
  • Excellent resistance to corrosion
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Finishing Options

Stainless Steel (316L)

Opt for 316L when flexibility is a priority, as it offers greater malleability compared to 17-4 PH. Parts manufactured from 316L undergo a stress relief treatment.

Key Advantages

  • Fully heat treated for maximum hardness and strength
  • Excellent corrosion resistance
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Finishing Options

Aluminum (AlSi10Mg)

Aluminum (AlSi10Mg) is similar to a 3000 series alloy commonly used in casting and die casting. It offers a strong strength-to-weight ratio, excellent resistance to high temperatures and corrosion, and good fatigue, creep, and rupture strength. Additionally, AlSi10Mg has notable thermal and electrical conductivity. Parts made from AlSi10Mg undergo a stress relief process.

Key Advantages

  • Excellent strength-to-weight ratio
  • Good thermal and electrical conductivity
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Custom Finishing Options

Inconel 718

Inconel 718 is a high-strength, corrosion-resistant nickel-chromium superalloy designed for parts subjected to extreme temperatures and mechanical stresses. It is ideal for aerospace, energy, and other high-performance applications where durability is crucial. Components made from Inconel 718 undergo stress relief treatment to optimize material properties. Additionally, solution and aging treatments per AMS 5663 are available to further enhance tensile strength and hardness, making it suitable for demanding environments.

Key Advantages

  • Excellent resistance to oxidation and corrosion
  • Outstanding tensile strength, fatigue resistance, creep strength, and rupture resistance
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Custom Finishing Options

Cobalt Chrome (Co28Cr6Mo)

Cobalt Chrome (Co28Cr6Mo) is a high-performance superalloy primarily composed of cobalt and chromium. It offers exceptional tensile strength, creep resistance, and corrosion resistance, making it an excellent choice for aerospace components and medical instruments.

Key Advantages

  • Superior tensile strength and creep resistance
  • Excellent corrosion resistance
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Custom Finishing Options

Titanium (Ti6Al4V)

Ti6Al4V is a widely used titanium alloy known for its excellent mechanical properties. Compared to annealed Ti grade 23, it offers similar tensile strength, elongation, and hardness to wrought titanium.

Key Advantages

  • Excellent strength-to-weight ratio with high rigidity
  • Resistant to high temperatures and corrosion
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Custom Finishing Options

Post-Processing Options for Metal 3D-Printed Parts

Enhance the strength, precision, and surface quality of metal components using DMLS for production.

Surface Finishing Options

  • 3- and 5-axis CNC milling
  • Precision turning
  • Custom surface treatments
  • Brushed finishes (150, 220, 400 grit)
  • Satin finish
  • Polished finish
  • Passivation for enhanced corrosion resistance
  • Wire EDM for fine detailing
  • Tapping and reaming for precise threading

Heat Treatment Options

  • Stress relief for reduced residual stress
  • NADCAP-certified heat treatment for aerospace compliance
  • Hot isostatic pressing (HIP) for improved density and mechanical properties
  • Solution annealing to enhance material uniformity
  • Aging to achieve desired strength and hardness

Mechanical Testing Options

  • Tensile strength evaluation
  • Rockwell hardness measurement

Powder Analysis & Material Traceability

  • Chemical composition verification
  • Particle size and distribution assessment

Benefits of Metal 3D Printing

Discover how metal additive manufacturing can streamline assemblies by reducing component count, enable the production of intricate geometries, and help save both time and costs.

Understanding the Metal 3D Printing Process with DMLS

The DMLS machine begins sintering each layer—first the support structures to the base plate, then the part itself—with a laser aimed onto a bed of metallic powder. After a cross-section layer of powder is micro-welded, the build platform shifts down and a recoater blade moves across the platform to deposit the next layer of powder into an inert build chamber. The process is repeated layer by layer until the build is complete.

When the build finishes, an initial brushing is manually administered to parts to remove a majority of loose powder, followed by the appropriate heat-treat cycle while still fixtured in the support systems to relieve any stresses. Parts are removed from the platform and support structures are removed from the parts, then finished with any needed bead blasting and deburring. Final DMLS parts are near 100 percent dense.

Large-Scale Metal 3D Printing

Our large-format 3D printers are capable of producing metal parts up to 31.5 inches x 15.7 inches x 19.7 inches in size, using materials such as Aluminum and Inconel. These large 3D-printed components are commonly utilized in industries such as aerospace, automotive, energy, and various industrial applications.

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