DMLS Production Parts
DMLS produces fully dense metal parts (99.5% theoretical density) directly from CAD files, without tooling, in 5–10 business days. Certified alloys with full mechanical data:
| Alloy | UTS | Density | Application |
|---|---|---|---|
| Ti6Al4V | 993–1,055 MPa | 4.43 g/cm³ | Aerospace, medical |
| 17-4 PH SS | 1,365–1,372 MPa | 7.78 g/cm³ | Tooling, aerospace |
| 316L SS | 565–586 MPa | 7.99 g/cm³ | Chemical, medical |
| AlSi10Mg | 268–345 MPa | 2.67 g/cm³ | Lightweight structures |
| Inconel 718 | 958 MPa | 8.19 g/cm³ | High-temperature |
| CoCrMo | 1,213–1,255 MPa | 8.30 g/cm³ | Dental, orthopedic |
Build envelopes: 9.6" × 9.6" × 13" standard; 31.5" × 15.7" × 19.7" large-format. Tolerances: ±0.003" + ±0.001"/in accumulated. Minimum feature: 0.006".
Design for DMLS (DfAM)
DMLS unlocks geometry impossible in machining or casting — but only if the design exploits the freedom rather than replicating conventional forms. Design for additive manufacturing (DfAM) at the DMLS level covers:
Topology optimization: Reduce mass 30–70% while maintaining stiffness targets. Tools: nTopology, Altair Inspire, ANSYS Mechanical. Input: load cases and constraints. Output: organic geometry with build-direction awareness.
Lattice structures: Replace solid infill with stochastic or periodic lattice. Gyroid, Schwartz diamond, and BCC lattices in 0.5–3 mm cell sizes achieve target densities while improving heat transfer and osseointegration in implants.
Support strategy: Self-supporting geometry above 45° eliminates support structures on internal channels. Below 45°: design-in supports, or orient to eliminate. Trapped powder removal requirements constrain blind channel design.
Thermal management: Conformal cooling channels in tooling inserts reduce injection mold cycle time 20–40%. Internal channel diameter ≥ 1 mm, no blind ends, continuous flow paths.
Post-Processing
DMLS parts require systematic post-processing to achieve production-grade mechanical properties and surface finish:
Stress relief (mandatory): 800°C / 2h vacuum for titanium; 650°C air or vacuum for steel. Performed before support removal to prevent distortion.
HIP (fatigue-critical parts): 900°C / 100 MPa / 2h for Ti6Al4V. Eliminates subsurface porosity, increases fatigue life 3–5×.
Machining: Post-print CNC milling and turning to ±0.001" on critical surfaces. Hybrid DMLS+CNC achieves near-machined accuracy on functional faces while retaining DMLS complexity in the bulk geometry.
Surface finish:
- Bead blast: Ra 1.6–3.2 µm (standard finish)
- Tumble/vibratory: Ra 0.8–1.6 µm
- Electropolish: Ra 0.4–0.8 µm (medical, food-contact)
- Mirror polish: Ra < 0.1 µm (optical, mold)
Coatings: Anodize (Ti, Al), PVD, thermal spray, electroplating.
Rapid Prototyping
Unlike polymer 3D printing, DMLS prototypes share the mechanical properties of production parts — same alloy, same process, same post-processing. Functional validation in the actual material is available in 48–72 hours for most alloys.
Rapid DMLS prototyping is appropriate when:
- Material properties must match production (stress analysis, fatigue testing)
- Geometry validation requires metal (machining fixtures, tooling trials)
- Regulatory submission requires the production material (FDA, AS9100)
- Timeline cannot accommodate machining lead time (4–6 weeks → 48 hours)
Minimum order: 1 part. No setup fee. File-to-first-article in 48 hours for standard alloys (Ti6Al4V, 316L, AlSi10Mg). 72 hours for Inconel and CoCrMo. Quote within 4 hours of file submission.