Metal 3D Printing Service (DMLS) | On-Demand Metal Parts

How DMLS Works: Fusing Metal with Light

Direct Metal Laser Sintering (DMLS) is an additive manufacturing process that builds parts layer-by-layer from a bed of fine metal powder. The process begins by spreading a thin layer of atomized metal powder onto a build platform.

Inside a chamber filled with inert gas, a high-power fiber laser selectively scans the cross-section of the part, melting and fusing the metal particles together on a molecular level. The build platform then lowers, a new layer of powder is applied, and the process repeats until the part is complete. The result is a fully dense, solid metal component with mechanical properties comparable to, or even exceeding, those of traditional cast or wrought metals.

A metal heatsink with complex fins for an automotive light, made with DMLS

The DMLS Advantage

DMLS is not a replacement for traditional machining, but a complementary technology that enables new possibilities.

Complex Geometries

Produce internal channels, conformal cooling, lattice structures, and organic shapes that are impossible to machine. Consolidate multiple machined components into a single, stronger printed part.

Part Lightweighting

Utilize topology optimization and generative design to create parts with an optimal strength-to-weight ratio, removing material where it isn't needed. This is critical for aerospace and high-performance automotive applications.

Accelerated Prototyping

Create functional metal prototypes for testing without the long lead times and high costs associated with casting or complex CNC setups. Iterate on your designs faster and with more confidence.

DMLS Materials and Applications

Common DMLS Metals

Stainless Steel (316L): Excellent corrosion resistance and good mechanical properties. Widely used for industrial hardware, medical tools, and consumer goods.
Aluminum (AlSi10Mg): Lightweight with good thermal properties. Ideal for heatsinks, lightweight brackets, and automotive components.
Titanium (Ti6Al4V): Very high strength-to-weight ratio and excellent biocompatibility. The top choice for medical implants and high-performance aerospace parts.
Inconel (IN718): A nickel superalloy that retains its strength at very high temperatures. Used for turbine blades, exhaust systems, and rocketry components.

Best-Fit Applications

Aerospace: Optimized brackets, fuel nozzles, and components for unmanned aerial vehicles (UAVs).
Medical: Custom surgical guides, patient-specific implants (PSI), and complex instrumentation.
Tooling & Molds: Conformal cooling inserts for injection molds that dramatically reduce cycle times.
Industrial: High-performance heat exchangers, custom manifolds, and replacement parts.

Metal 3D Printing FAQ

What is the surface finish of a DMLS part?

As-printed DMLS parts have a matte, slightly rough surface finish, similar to a fine casting. They can be post-processed via bead blasting for a uniform finish or CNC machined on critical features to achieve very smooth surfaces and tight tolerances.

Are DMLS parts as strong as machined parts?

Yes. DMLS produces fully dense metal parts with mechanical properties that are typically comparable or superior to cast parts and very close to those of wrought (machined) materials. In some cases, the fine grain structure can even lead to improved strength.

Is metal 3D printing expensive?

Metal 3D printing can have a higher per-part cost than CNC machining for simple geometries. However, its value becomes clear when producing highly complex, consolidated, or lightweighted parts that would be impossible or prohibitively expensive to make with traditional methods. It trades higher material cost for nearly unlimited design freedom.