Direct Metal Laser Sintering

DMLS fuses metal powder layer-by-layer with a precision laser to produce dense, functional metal parts directly from CAD with no tooling required.

Design and preparation

Begin with a CAD model optimized for additive manufacturing (DfAM); choose the appropriate alloy and define critical tolerances and mating surfaces. Save the design as an STL or 3MF file, position it to reduce support needs, and integrate any required support structures. Confirm material specs and printing strategy before moving to slicing.

Slicing and build setup

Slice the model into thin layers and select process parameters such as layer thickness, hatch spacing, laser power, and scan speed. Arrange parts on the build plate for thermal balance and efficient powder use, then load the chosen metal powder into the machine. Set the chamber atmosphere (argon or nitrogen) and verify oxygen levels are within acceptable limits.

Powder spreading and layer deposition

A recoater spreads a uniform powder layer across the build platform; layer thickness equals the chosen slice height. Powder characteristics (spherical morphology, ~15–45 µm particle size) and even spreading are critical to avoid defects. Unused powder is collected, sieved, and prepared for reuse under strict quality controls.

Laser fusion and layer-by-layer building

A high-powered laser selectively melts the powder according to the sliced paths, creating metallurgical bonds to the previous layer. Scan strategies and energy density are tuned to achieve >99% density while controlling residual stress and microstructure. The machine repeats the spread–scan cycle until the part is complete, with in-process monitoring detecting anomalies when available.

Cooling and post-processing

Controlled cooling helps prevent deformation; afterward, the build plate is detached and supports are eliminated using machining, EDM, or grinding techniques. Perform necessary heat treatments (stress relief, HIP), finish critical surfaces by machining or polishing, and apply surface treatments as required. 

What are the Advantages of Using DMLS in Manufacturing?

DMLS offers exceptional design freedom, high-strength parts, and faster turnaround compared to traditional methods, making it ideal for complex, high-performance components.

Unmatched Design Flexibility

DMLS enables engineers to create geometries that are impossible or prohibitively expensive with CNC machining or casting. Internal channels, lattice structures, and organic shapes can be produced without tooling constraints. This opens up opportunities for weight reduction of up to 60% in aerospace and automotive components.

High-Strength Functional Parts

Parts made via DMLS can achieve densities of over 99%, matching or even exceeding the mechanical properties of wrought metals. This makes them suitable for load-bearing and mission-critical applications in aerospace, defense, and medical implants.

Reduced Production Lead Time

Since no molds or tooling are required, production can start as soon as the design is finalized. Prototypes can be manufactured in days instead of weeks, accelerating product development cycles and enabling faster time-to-market.

Sustainability and Waste Reduction

Unlike subtractive methods that can waste up to 90% of the material, DMLS uses powder-bed fusion where unused powder is recovered and reused. This results in minimal waste and better material utilization.

Integrated Component Manufacturing

Multiple components can be combined into a single printed part, reducing assembly time, potential failure points, and inventory requirements. For example, an assembly of 12 parts can often be consolidated into 1–2 printed pieces.