DMLS

Direct Metal Laser Sintering (DMLS) is an additive manufacturing process which uses CAD data to grow metal prototypes and production parts layer-by-layer. Powdered metal is dispersed across the machine’s base plate in 20, 30, or 40 micron layers (depending on material), then heated and sintered to the base plate. This process is repeated for each remaining layer until the full part is built. Once the process is complete, the base plate is raised, and excess powder is removed.

DMLS is ideal for creating high-quality, metal parts quickly. Unlike tooling, which can take a few weeks to complete, DMLS parts can be completed in a matter of days. This quick turnaround aids in the ability for design change and rebuilds.

Advantages of Direct Metal Laser Sintering (DMLS)

Intricate geometries and fine detail
Quick and cost effective
Extremely dense (99.8%)
Excellent for functionality testing

Examples:

DMLS Laser Reproductions Laser Reproductions DMLS

Machines:

EOS M270

Build Size:

9″ X 9″ X 7.5″

228 X 228 X 190 mm

EOS M280

Build Size

9″ X 9″ X 12″

228 X 228 X 304 mm

Materials:

Material	Characteristics	Applications
Stainless Steel 17-4	20 or 40 Micron Layers 20-25 HRC As Built 45 HRC Post Hardened Max Temp – 550°C, 1022°F	Parts requiring high corrosion resistance, sterile Parts requiring particularly high toughness and ductility
Stainless Steel 15-5	20 or 40 Micron Layers 30-35 HRC As Built 40 HRC Post Hardened Max Temp – 460°C, 860°F	Parts requiring high corrosion resistance, sterile Parts requiring particularly high hardness and strength
Cobalt Chrome	20 or 40 Micron Layers 40-45 HRC As Built Max Temp – 1150°C, 2100°F	Parts requiring high mechanical properties in elevated temperatures and with good corrosion resistance e.g. Turbines and other parts for engines, cutting parts Parts having very small features such as thin walls, pins requiring particularly high strength and stiffness
Maraging Steel (Tooling Steel)	20 or 40 Micron Layers 33-37 HRC As Built 50-54 HRC Post Hardened Max Temp – 400°C, 750°F	Heavy duty injection molds and inserts for molding all standard thermoplastics using standard injection parameters, with achievable tool life of millions of parts Die casting molds for several thousand parts in light alloys Parts requiring particularly high strength and hardness
Bronze (DM20)	20 Micron Layers 115 HV As Built Max Temp – 400°C, 750°F	Injection molds and inserts for molding tens or hundreds of thousands of parts in standard thermoplastics using standard injection parameters Soft Tooling
Titanium Alloy (Ti64)	30 Micron Layers 41-44 HRC As Built Max Temp – 350°C, 660°F	Parts requiring a combination of high mechanical properties and low specific weight e.g. Structural and engine components for aerospace and motorsport applications Biomedical implants
Aluminum (AlSi10mg)	30 Micron Layers 120 ± 5 HBW As Built 112 ± 5 HBW Post Hardened	Parts requiring a combination of good thermal properties with low weight e.g. Motorsport applications
Nickel Alloy (IN718) (Inconel)	20 Micron Layers 30 HRC As Built 47 HRC Post Hardened Max Temp – 650°C, 1200°F	Aero and land based turbine engine parts Rocket and space application components Chemical and process industry parts Oil well, petroleum and natural gas industry parts

DMLS Finish Levels:

Unfinished (Includes removal of support material)
Shot Peened
Sand Blasted
Brushed Finish
Lightly Sanded
Medium Polished
Mirror Polished

Additional Finishing Options:

Abrasive Blast (Grit & Ceramic)
Electrochemical Polishing
Abrasive Flow Machining (Extrude Hone) Polishing
Electroplating
Micro Machining Process (MMP)
CNC Finishing/Machining

Additional Services:

Laser welding of DMLS parts
Laser engraving of DMLS parts

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