DMLS TechnologyMetal

Aluminum AlSi10MgLightweight High-Performance Metal Alloy

Aluminum AlSi10Mg is a versatile casting alloy optimized for DMLS additive manufacturing. Combining exceptional strength-to-weight ratio with excellent thermal conductivity and corrosion resistance, it delivers consistent mechanical properties ideal for aerospace, automotive, and industrial applications requiring lightweight, high-strength components.

Tensile Strength
460 MPa
Flexural Modulus
75 GPa
Temperature Resistance
300 °C
Technology
DMLS
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Aluminum AlSi10Mg 3D printed part example
Metal Precision
Industrial Grade
DMLS material

Aluminum AlSi10Mg overview

Aluminum AlSi10Mg is a casting alloy specifically optimized for Direct Metal Laser Sintering (DMLS) additive manufacturing. This versatile material combines the lightweight properties of aluminum with silicon and magnesium additions that enhance strength, hardness, and castability. The DMLS process produces parts with fine microstructure similar to T6 heat-treated conventional castings, delivering exceptional mechanical properties in the as-built condition. With excellent thermal conductivity, corrosion resistance, and the ability to produce gas-tight parts, AlSi10Mg is ideal for applications requiring lightweight, high-performance metal components.

Why manufacture with Aluminum AlSi10Mg

Aluminum AlSi10Mg combines excellent strength-to-weight ratio for lightweight designs and high thermal conductivity (103-119 w/m·k) for heat management, delivering outstanding corrosion resistance in harsh environments for demanding applications. From rapid prototyping to production runs, teams rely on Aluminum AlSi10Mg to maintain tight tolerances while reducing assembly complexity through consolidated part designs.

DMLS Production Technology

EOS metal systems define the industry benchmark for direct metal laser sintering, incorporating precision optics with f-theta lenses that maintain consistent beam quality across the entire build platform. Their closed-loop powder handling and inert atmosphere control achieve oxygen levels below 0.1%, critical for reactive materials like titanium and aluminum alloys. The EOSTATE monitoring suite provides real-time melt pool analysis and automatic exposure parameter correction, ensuring aerospace-grade quality with full documentation for every layer of every part.

Build Volume

250 × 250 × 325 mm

Max part size

Lead Time

8-12 business days

Standard production

Layer Height

0.03 - 0.06 mm

Resolution

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Manufactured in Forge Labs' North American production centers with serialized traceability for Aluminum AlSi10Mg.

Aluminum AlSi10Mg DMLS cube sample showing aerospace-grade metal properties
Technical resources

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Navigate directly to the property tables and grab the latest datasheet for your build review.

Technical datasheet

Detailed specs for Aluminum AlSi10Mg.

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Applications & field work

Where Aluminum AlSi10Mg excels

Aluminum AlSi10Mg through EOS DMLS delivers lightweight components with complex internal channels and thin-wall features impossible to machine. Our EOS systems achieve fine microstructure with silicon networks that provide excellent strength without heat treatment.

The rapid solidification in DMLS creates a unique microstructure with strength approaching 6061-T6 while maintaining good ductility. Parts can be machined, welded, and anodized using standard aluminum processes, integrating seamlessly with traditional components.

Forge Labs' optimized parameters minimize porosity to <0.5% while achieving surface roughness Ra 9-12 μm as-built. Our stress relief and optional T6 heat treatment protocols deliver consistent properties for production applications.

Mechanical
Tensile Strength (XY): 460 MPa
Yield 240 MPa, UTS 390 MPa
Thermal
Thermal Conductivity (XY): 103 W/m·K
Conductivity 130 W/m·K
Physical
Density: 2.67 g/cm³
Chemical
Excellent with Seawater
High-precision aluminum component
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Manufacturing intelligence for Aluminum AlSi10Mg

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Industry applications for Aluminum AlSi10Mg

From aerospace heat exchangers to automotive pistons, DMLS AlSi10Mg enables lightweight designs with integrated functionality. Explore how industries leverage this versatile aluminum alloy.

DMLS AlSi10Mg enables conformal cooling channels and complex heat exchanger geometries for aerospace thermal management. The process achieves thin walls down to 0.8mm for weight optimization.

Key Applications

  • Heat exchangers with gyroid structures
  • Electronic housing with integrated cooling
  • Lightweight brackets and fixtures
  • UAV structural components

Performance Data

Thermal conductivity 130 W/m·K with 40% weight reduction versus traditional heat exchangers, meeting aerospace cooling requirements.

Explore aerospace thermal management

Automotive manufacturers use DMLS AlSi10Mg for prototype and low-volume production parts requiring weight reduction. The technology enables consolidated assemblies and optimized designs.

Key Applications

  • Pistons with conformal cooling galleries
  • Turbocharger housings and impellers
  • Suspension components and nodes
  • Electric motor housings

Performance Data

Achieves 345 MPa yield strength with 30% weight savings versus cast aluminum, enabling efficient powertrains and chassis.

Explore automotive lightweighting

DMLS AlSi10Mg revolutionizes injection mold inserts with conformal cooling that reduces cycle times up to 40%. The process enables cooling channels that follow part contours precisely.

Key Applications

  • Injection mold inserts with conformal cooling
  • Blow mold tooling components
  • Die casting dies for prototype runs
  • Thermoforming tools

Performance Data

Reduces injection molding cycle time by 20-40% with uniform part cooling, achieving ROI within 5,000 cycles for many applications.

Electronics manufacturers leverage DMLS AlSi10Mg for EMI shielding enclosures and heat sinks with optimized fin geometries. The material's conductivity provides effective thermal and electrical performance.

Key Applications

  • RF shielding enclosures
  • LED heat sinks with maximum surface area
  • Waveguides and antenna components
  • 5G infrastructure cooling solutions

Performance Data

Electrical conductivity 20 MS/m with complex internal geometries for 50% improved cooling versus machined heat sinks.

Explore electronic enclosures

Aluminum AlSi10Mg production examples

High-precision aluminum component

High-precision aluminum component

Lightweight Structural Component

AlSi10Mg structural bracket demonstrating lightweight design

AlSi10Mg structural bracket demonstrating lightweight design

Structural Applications

DMLS production capabilities

DMLS production capabilities

Manufacturing Solutions

Performance Dashboard

Technical performance for Aluminum AlSi10Mg

Aluminum AlSi10Mg delivers dependable strength and impact resistance for Aircraft structural components and brackets and Automotive engine parts and heat exchangers, helping teams move from prototype to production with confidence.

Mechanical Properties

Tensile Strength (XY)

460 MPa

Tested to ASTM E8

Aluminum AlSi10Mg records Tensile Strength (XY) at 460 MPa, reinforcing its mechanical properties story.

Mechanical Properties

Tensile Strength (Z)

460 MPa

Tested to ASTM E8

Aluminum AlSi10Mg records Tensile Strength (Z) at 460 MPa, reinforcing its mechanical properties story.

Mechanical Properties

Yield Strength (XY)

270 MPa

Tested to ASTM E8

Aluminum AlSi10Mg records Yield Strength (XY) at 270 MPa, reinforcing its mechanical properties story.

Aluminum AlSi10Mg combines Excellent strength-to-weight ratio for lightweight designs and High thermal conductivity (103-119 W/m·K) for heat management to support Aircraft structural components and brackets and Automotive engine parts and heat exchangers that demand production-ready durability.

Measurement
Aluminum AlSi10MgBase
Standard
Tensile Strength (XY)460 MPaASTM E8
Tensile Strength (Z)460 MPaASTM E8
Yield Strength (XY)270 MPaASTM E8
Yield Strength (Z)240 MPaASTM E8
Flexural Strength520 MPa—
Elastic Modulus (XY)75 GPaASTM E8
Elastic Modulus (Z)70 GPaASTM E8
Elongation at Break (XY)9 %ASTM E8
Elongation at Break (Z)6 %ASTM E8
Hardness (Brinell)119 HBWASTM E10
Fatigue Strength (Z)97 MPaASTM D7791
Mechanical Performance

Mechanical Properties

Aluminum AlSi10Mg delivers dependable strength and impact resistance for Aircraft structural components and brackets and Automotive engine parts and heat exchangers, helping teams move from prototype to production with confidence.

Aluminum AlSi10Mg delivers exceptional mechanical performance with excellent strength characteristics, effectively handling demanding load conditions. Its balanced mechanical profile allows it to maintain structural integrity while preventing brittleness in critical applications.

These qualities make it well-suited for Aircraft structural components and brackets, Automotive engine parts and heat exchangers, and Electronic device cooling systems and heat sinks, providing long-term durability in demanding environments. Aluminum AlSi10Mg maintains dimensional stability over time, ensuring consistent performance across temperature and stress variations.

This makes it a reliable choice for applications requiring precise geometries and tight tolerances across Aerospace, Automotive, and Electronics. Its versatility and durability allow it to perform consistently across a wide range of mechanical applications, ensuring parts maintain their integrity under repetitive stress and environmental conditions.

Aluminum AlSi10Mg combines Excellent strength-to-weight ratio for lightweight designs and High thermal conductivity (103-119 W/m·K) for heat management to support Aircraft structural components and brackets and Automotive engine parts and heat exchangers that demand production-ready durability.

Key metric

Tensile Strength (XY)

460 MPa

Tested to ASTM E8

Key metric

Tensile Strength (Z)

460 MPa

Tested to ASTM E8

Key metric

Yield Strength (XY)

270 MPa

Tested to ASTM E8

Dive into the data

Detailed mechanical measurements live in the performance dashboard above. Switch tabs to compare against other materials instantly.

Material Makeup

Physical Properties

Aluminum AlSi10Mg offers consistent density and surface quality so critical features hold tolerances and downstream finishing remains predictable.

Aluminum AlSi10Mg exhibits a density of 2.67 g/cm³ that contributes to lightweight yet durable parts. Its low moisture absorption ensures dimensional stability in varying environmental conditions.

These physical properties enable consistent part quality and predictable performance across Aircraft structural components and brackets, Automotive engine parts and heat exchangers, and Electronic device cooling systems and heat sinks. The material's inherent characteristics minimize warpage and maintain tight tolerances throughout the part lifecycle.

For Aerospace, Automotive, and Electronics, these physical attributes translate to reliable production outcomes with minimal post-processing requirements, ensuring parts meet specifications straight from the build platform.

Aluminum AlSi10Mg delivers 2.67 g/cm³ density and 6-10 μm Ra surface finish so assemblies fit and finish without secondary rework.

Key metric

Density

2.67 g/cm³

Tested to ASTM B311

Key metric

Relative Density

99.85 %

Key metric

Electrical Conductivity

18-22 MS/m

Tested to ASTM B193

Dive into the data

Detailed physical properties measurements live in the performance dashboard above. Switch tabs to compare against other materials instantly.

Heat Performance

Thermal Properties

Aluminum AlSi10Mg maintains dimensional stability through temperature swings, making it a reliable option for Aerospace and Automotive programs that see repeated thermal cycling.

Aluminum AlSi10Mg demonstrates excellent thermal stability with robust heat resistance, enabling it to maintain dimensional accuracy in elevated temperature environments. This thermal performance ensures parts retain their shape and mechanical properties even under thermal stress.

The material's thermal characteristics make it ideal for Aircraft structural components and brackets, Automotive engine parts and heat exchangers, and Electronic device cooling systems and heat sinks that experience temperature fluctuations. Its ability to withstand thermal cycling without degradation ensures long-term reliability in Aerospace, Automotive, and Electronics.

With an operating temperature range up to 300 °C, Aluminum AlSi10Mg provides engineers with confidence when designing parts for thermally demanding applications, from under-hood automotive components to industrial equipment exposed to heat sources.

Aluminum AlSi10Mg maintains geometry with a Service Temperature of 300 °C, protecting dimensional integrity during heat cycling.

Key metric

Thermal Conductivity (XY)

103 W/m·K

Tested to ASTM E1461

Key metric

Thermal Conductivity (Z)

119 W/m·K

Tested to ASTM E1461

Key metric

Specific Heat Capacity

920 J/kg·K

Tested to ASTM E1269

Dive into the data

Detailed thermal properties measurements live in the performance dashboard above. Switch tabs to compare against other materials instantly.

Compatibility Data

Chemical Properties

Aluminum AlSi10Mg offers tested chemical resistance across acids, bases, solvents, and hydrocarbons to ensure reliable performance in harsh environments.

Aluminum AlSi10Mg demonstrates broad chemical resistance with testing against 10 different chemicals, showing excellent compatibility with 4 substances and good compatibility with 4 others. This extensive chemical resistance profile makes it suitable for harsh industrial environments.

The material's resistance to acids, bases, solvents, and hydrocarbons enables its use in Aircraft structural components and brackets, Automotive engine parts and heat exchangers, and Electronic device cooling systems and heat sinks that require exposure to aggressive chemicals. Its chemical inertness ensures parts maintain their mechanical properties even after prolonged chemical exposure.

For Aerospace, Automotive, and Electronics, this chemical stability translates to longer service life and reduced maintenance requirements, making Aluminum AlSi10Mg a cost-effective choice for chemically demanding applications.

Aluminum AlSi10Mg has been tested against 10 chemicals with 4 showing excellent compatibility for demanding chemical environments.

Key metric

Seawater

Excellent

Type: Salt Solution

Key metric

Atmospheric Corrosion

Excellent

Type: Oxidizer

Key metric

Motor Oil

Excellent

Type: Hydrocarbon

Dive into the data

Detailed chemical properties measurements live in the performance dashboard above. Switch tabs to compare against other materials instantly.

Chemical Resistance

Chemical compatibility for Aluminum AlSi10Mg

Evaluate how Aluminum AlSi10Mg responds to common chemicals before you commit to production tooling. Filter the grid to focus on acids, bases, solvents, or hydrocarbons.

10 of 10 chemicals shown

ChemicalTypeCompatibility
SeawaterSalt SolutionExcellent
Atmospheric CorrosionOxidizerExcellent
Alkaline SolutionsBaseGood
Weak AcidsAcidGood
Motor OilHydrocarbonExcellent
Hydraulic FluidsHydrocarbonExcellent
Strong Acids (HCl, H2SO4)AcidPoor
Strong Bases (NaOH)BaseModerate
Organic SolventsSolventGood
Fuel SystemsHydrocarbonGood to Excellent
Resources

Datasheets and design resources

Equip your team with certification packs, design guides, and spec sheets tailored to Aluminum AlSi10Mg.

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Access the most recent datasheet and supporting documentation maintained by our engineering team.

Resources

Material DatasheetMechanical Properties Overview

Design guidelines

Explore printable geometry recommendations, wall thickness tips, and finishing playbooks for DMLS.

View DMLS design guide

Compliance certificates

Keep your quality packet current with pre-approved certifications.

DIN EN 1706 (EN AC-43000)Certified
ASTM F3318Certified
ISO 9001:2015Certified

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Advanced Manufacturing

Built with Precision DMLS Technology

Aluminum AlSi10Mg is manufactured using Direct Metal Laser Sintering (DMLS) technology, providing unmatched strength and precision for mission-critical applications.

DMLS Manufacturing Lab

Aluminum AlSi10Mg is printed on EOS M-series production systems with real-time melt pool monitoring, guaranteeing aerospace-grade density and fatigue performance for tooling and end-use components.

Process Parameters

Layer Height
0.03 - 0.06 mm
Tolerance
± 0.1 mm (± 0.1%)
  • Build Volume: 250 × 250 × 325 mm. Large production capacity enables efficient manufacturing of multiple parts or assemblies.
  • Quality Control. In-process monitoring and batch traceability ensure consistent part quality and material properties.

Finishing Options

Support removalStress reliefMachiningShot peeningPolishingAnodizingHeat treatment
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Frequently Asked Questions

Frequently asked questions about Aluminum AlSi10Mg

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Aluminum AlSi10Mg is known for its excellent strength-to-weight ratio for lightweight designs, high thermal conductivity (103-119 w/m·k) for heat management, outstanding corrosion resistance in harsh environments, making it suitable for aerospace and automotive applications.

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