Direct Metal Laser Sintering (DMLS)

Direct Metal Laser Sintering was revolutionary in that it finally gave the manufacturing world the ability to rapidly 3D print complex metal geometries without compromising metallic material properties. Three-dimensional parts made by this process once started as powder sized at 20μm in a powder bed before a high-power laser melted it with intense heat layer by layer into a pre-programed shape. With repeated layer-by-layer (additive) manufacturing, the fully dense metal part is made.
DMLS is ideal in manufacturing fully functional and very complex geometries equal to that of a part that requires fifth-axis milling or an investment casting. It can also be used to reduce cost and create what would normally be a two-piece or more welded assembly if designed correctly for the process. Because the technology requires support structure made from the same alloy as the part, design awareness is crucial for proper part manufacturing.

REQUEST A QUOTE

// Old Switcher-hidden

Resources

Tech Sheets
There are a large variety of secondary services that can and in some cases should be performed depending on the alloy being printed.

For Surfaces:
- Finish CNC (3- and 5-axis milling)
- Turning
- Wire EDM
- Polishing
- Plating
- Passivation
- Anodizing
- Tapping and Reaming
- Hardware Installation
- Powder Coating
- Assembly
For Heat Treatments:
- Hot Isostatic Pressing (HIP)
- Solution Annealing
- Aging
- Stress Relieving
- NADCAP
For Powder Analysis:
- Chemistry
- Particle Size Analysis
- Traceability
For Testing:
- Tensile Bar Pull
- Rockwell Hardness
- X-Ray
- Stress Testing

Post Processes

There are a large variety of secondary services that can and in some cases should be performed depending on the alloy being printed.

For Surfaces:

Finish CNC (3- and 5-axis milling)
Turning
Wire EDM
Polishing
Plating
Passivation
Anodizing
Tapping and Reaming
Hardware Installation
Powder Coating
Assembly

For Heat Treatments:

Hot Isostatic Pressing (HIP)
Solution Annealing
Aging
Stress Relieving
NADCAP

For Powder Analysis:

Chemistry
Particle Size Analysis
Traceability

For Testing:

Tensile Bar Pull
Rockwell Hardness
X-Ray
Stress Testing

Technical Info

Layer thickness for all builds is commonly at 40μm and can be increased to 60 μm and decreased to 20μmParts can be printed in a single piece as large as 15” x 15” x 15”

Tolerances for as-printed parts are + 0.010” throughout

Wall thickness should be designed at 0.030” (supported)

Wall thickness should be designed at 0.039” (unsupported)

Minimum feature size 0.015” but 0.020” is optimal

Minimum hole size is 0.030” and in some cases can be as thin as 0.022”

Lettering should be designed at 0.19” tall or deep with a minimum font size of 14

Fillets are valuable in that they reduce stress which tends to occur with DMLS metal 3D printing

Improved tolerances can be achieved by adding approximately 0.045” worth of stock to all areas where finish CNC is desired. Finish CNC can achieve improved tolerances of + 0.0005”