The DMLS material menu has expanded, but six alloys cover the vast majority of production applications. Correct selection at the design stage prevents the $5,000–$50,000 cost of discovering the wrong material after build.
Decision Framework
- Temperature requirement: Above 300°C sustained? → Inconel 718 or Ti6Al4V
- Biocompatibility: Skin contact or implantable? → Ti6Al4V ELI or CoCrMo (ASTM F136/F75)
- Weight constraint: Below 5 g/cm³? → Ti6Al4V (4.43) or AlSi10Mg (2.67)
- Strength target: Above 900 MPa UTS? → Ti6Al4V, 17-4 PH (H900), or CoCrMo
- Cost sensitivity: Price-driven? → AlSi10Mg or 316L (lowest DMLS powder cost)
Alloy Profiles
Ti6Al4V — The Versatile High-Performer
- UTS: 993–1,055 MPa (as-built + stress relief)
- Density: 4.43 g/cm³ — best strength-to-weight ratio in the DMLS catalog
- Temperature: Continuous to 300°C; usable to 400°C
- Cost: High (powder ~$400–600/kg)
- Best for: Aerospace structures, medical implants, motorsport components
- Not for: High-temperature above 400°C, corrosive aqueous environments (use 316L)
316L Stainless — The Chemical Workhorse
- UTS: 565–586 MPa (low for the alloy family; compensate with wall thickness)
- Elongation: 50% — most ductile DMLS metal; absorbs shock
- Corrosion: Outstanding; passes 480-hour salt spray
- Cost: Low-medium (~$100–150/kg powder)
- Best for: Chemical processing, food equipment, marine hardware
- Not for: High-strength structural (use 17-4 PH); high temperature (use Inconel)
17-4 PH — The High-Strength Stainless
- UTS: 1,365–1,372 MPa after H900 aging — nearly 3× stronger than 316L
- Hardness: 50–52 HRC after aging
- Cost: Medium (~$150–200/kg)
- Best for: Tooling, aerospace brackets, firearms components, structural hardware
- Not for: Corrosive environments at pH < 4 (use 316L)
AlSi10Mg — Lightweight Structural Aluminum
- UTS: 268–345 MPa (lower than wrought 6061-T6)
- Density: 2.67 g/cm³ — 40% lighter than titanium
- Cost: Low (~$80–120/kg)
- Best for: Lightweight housings, automotive brackets, heat sinks
- Not for: High-temperature, fatigue-critical (lower fatigue limit than Ti or steel)
Inconel 718 — High-Temperature Nickel
- UTS: 958 MPa (comparable to Ti6Al4V but at 700°C)
- Temperature: Continuous service to 700°C; usable to 980°C
- Cost: Very high (~$400–800/kg)
- Best for: Gas turbine components, rocket engines, downhole oil/gas
- Not for: Weight-critical (8.19 g/cm³); cost-sensitive applications
CoCrMo — The Implant Standard
- UTS: 1,213–1,255 MPa — highest as-printed strength
- Biocompatibility: ASTM F75 implant grade; excellent osseointegration
- Cost: High (~$300–500/kg)
- Best for: Orthopedic implants, dental prosthetics, wear-resistant tooling
- Not for: Weight-critical (8.30 g/cm³); aqueous corrosion environments