Compare SLS, MJF, SLA, DMLS, FDM, and CNC production technologies. Access specifications, material compatibility, and design rules in an interactive guide.
| Technology | Build Volume | Layer Height | Tolerance | Lead Time | Materials |
|---|---|---|---|---|---|
 CNC Machining subtractive•CNC Aerospace BracketsMedical Instrumentation+2 more | 1000×600×500mm (39×24×20") | N/A (subtractive machining) | ±0.020mm | 12-16 business days | 7 available |
 Direct Metal Laser Sintering metal•DMLS Aerospace ComponentsMedical Devices+2 more | 380 × 284 × 380 mm (15 × 11.2 × 15 in) | 0.02 - 0.06 mm | ±0.2mm | 8-12 business days | 6 available |
 Fused Deposition Modeling thermoplastic•FDM Aerospace ComponentsAutomotive Manufacturing+2 more | 914 × 609 × 914 mm (36" × 24" × 36") | 127 - 330 microns | ±0.25mm | 2-4 business days | 7 available |
 Fused Filament Fabrication thermoplastic•FFF Concept ValidationDesign Iteration+1 more | 250 × 210 × 210 mm (9.8" × 8.3" × 8.3") | 50 - 300 microns | ±0.5mm | 1-3 business days | 4 available |
 Multi-Jet Fusion thermoplastic•MJF Aerospace ComponentsAutomotive Manufacturing+2 more | 380 × 284 × 380 mm (15 × 11.2 × 15 in) | 80 microns | ±0.3% | 4-8 business days | 2 available |
 PolyJet Matrix resin•PolyJet Multi-Material PrototypesMedical & Anatomical Models+2 more | 380 × 284 × 380 mm (15 × 11.2 × 15 in) | 0.028 mm (28 microns) | ±0.2% | 2-4 business days | 3 available |
 Stereolithography resin•SLA Visual PrototypesJewelry & Detailed Parts+3 more | 1500 × 750 × 550 mm (59 × 29.5 × 21.7 in) | 0.025 - 0.150 mm | ±0.25% | 2-4 business days | 5 available |
Selective Laser Melting metal•SLM Aerospace ComponentsMedical Implants+1 more | 250 × 250 × 325 mm (10 × 10 × 13 in) | 0.02 - 0.05 mm | ±0.1mm | 10-14 business days | 4 available |
 Selective Laser Sintering thermoplastic•SLS Aerospace ComponentsMedical Devices+2 more | 340 × 340 × 600 mm (13.4 × 13.4 × 23.6 in) | 60 - 120 microns | ±0.25% | 2-4 business days | 4 available |
Benchmark polymer, metal, and hybrid manufacturing platforms by envelope, resolution, tolerances, and supported materials. Access the interactive database above to align the right process with program requirements.
Production-ready polymer, metal, resin, and CNC platforms under one roof.
Process-locked powders, resins, and billets with traceable documentation.
34+ industries spanning aerospace, medical, energy, and consumer products.
Align your tolerance stack, surface finish goals, and production plan with the platforms that excel in those areas. These benchmarks pull directly from our qualified machines and are backed by inspection data.
Large-format SLA enables full-scale prototypes, automotive panels, and industrial housings in a single build without segmentation.
Ideal for visual prototypes, design validation, and customer presentations requiring full-scale accuracy.
From standard ABS to high-performance ULTEM and PC, FDM offers engineering-grade thermoplastics for diverse application requirements.
Pre-qualified materials with documented properties enable rapid material selection and qualification.
SLS enables dense part nesting without support structures, maximizing build chamber utilization for rapid turnaround on production volumes.
Powder bed technology allows efficient batch production with consistent quality across all parts.
DMLS produces fully dense metal parts from titanium, stainless steel, aluminum, and Inconel for aerospace, medical, and industrial applications.
Complete thermal management and post-processing capabilities deliver production-ready metal components.
Our manufacturing capabilities span polymer additive, metal additive, resin-based, and precision subtractive platforms. Each technology family delivers distinct advantages for specific material requirements, tolerance demands, and production volumes. From rapid prototyping to production-scale manufacturing, our industrial equipment and process expertise enable consistent quality across aerospace, medical device, automotive, and consumer product applications.
Powder bed fusion technologies build parts layer by layer in a bed of thermoplastic powder, eliminating the need for support structures and enabling dense part nesting for efficient production. Both SLS and MJF deliver strong, functional nylon parts with isotropic mechanical properties, making them ideal for end-use applications. The self-supporting nature of powder bed processes allows complex geometries, snap fits, and living hinges that would be difficult or impossible with other additive methods.
Build functional prototypes and production parts without support structures, reducing post-processing time and material waste. Achieve efficient part nesting within the build chamber, maximizing throughput for bridge production and low-volume manufacturing runs. Access comprehensive finishing options including color dyeing, vapor smoothing, and cosmetic painting to meet aesthetic and functional requirements.
Support-free manufacturing of complex geometries using engineering-grade nylon materials. High mechanical strength with uniform properties for functional prototypes and production parts with cost-effective batch manufacturing. This technology operates with build volumes up to 340 × 340 × 600 mm, achieving layer heights from 60 - 120 microns and maintaining tolerances of ±0.25% (Lower limit of ±0.25 mm).
Precision engineering with fine detail resolution and excellent surface quality. Production-grade materials for strength and durability with scalable batch production. This technology operates with build volumes up to 380 × 284 × 380 mm, achieving layer heights from 80 microns and maintaining tolerances of ±0.3%, Lower limit of ±0.5 mm.
Both SLS (Selective Laser Sintering) and MJF (Multi Jet Fusion) are powder bed fusion technologies that build parts in a bed of nylon powder without support structures. While they share similar principles, MJF uses inkjet-applied agents and infrared energy, whereas SLS uses a laser to fuse powder. Each offers distinct advantages for different production scenarios.
Note: Both technologies produce strong, functional nylon parts without supports. Choose SLS for proven material variety and established processes, or MJF for faster production, better surface finish, and higher throughput applications.
Material extrusion technologies build parts by depositing molten thermoplastic layer by layer. Industrial FDM (Stratasys) delivers engineering-grade performance, while FFF systems serve concept validation and prototyping needs.
Industrial FDM provides heated chamber control (90°C+), ±0.127mm accuracy, and engineering thermoplastics like PEEK, ULTEM, and Polycarbonate. FFF systems (Prusa, Ultimaker) offer accessible prototyping with PLA, ABS, and PETG at ±0.3-0.5mm accuracy for non-critical applications. Both technologies share material extrusion fundamentals but differ significantly in thermal management, precision mechanics, and material certification.
Industry-leading precision with best-in-class repeatability and layer adhesion using industrial-grade thermoplastics. This technology operates with build volumes up to 914 × 609 × 914 mm, achieving layer heights from 127 - 330 microns and maintaining tolerances of ±0.25 mm (Fortus 450) / ±0.762 mm (Fortus 900).
Accessible extrusion-based 3D printing for rapid concept validation, design iteration, and non-critical prototyping with standard thermoplastic filaments. This technology operates with build volumes up to 250 × 210 × 210 mm, achieving layer heights from 50 - 300 microns and maintaining tolerances of ±0.3-0.5 mm typical.
Within polymer extrusion, FDM (Fused Deposition Modeling) refers specifically to Stratasys's industrial-grade trademarked technology, while FFF (Fused Filament Fabrication) describes the broader category of consumer and prosumer extrusion printers. Though fundamentally similar in principle, these technologies differ significantly in precision, thermal control, and material capabilities.
Note: Forge Labs operates both industrial FDM systems and a Prusa FFF farm. While FFF is not a core production technology, it serves valuable roles in rapid concept validation and non-critical prototyping. For engineering applications requiring dimensional accuracy or material certification, industrial FDM remains the appropriate choice.
Photopolymer resin technologies cure liquid materials using UV light to create parts with exceptional surface quality and fine feature resolution. SLA uses laser-based vat photopolymerization for high-accuracy single-material parts, while PolyJet employs inkjet deposition for multi-material capabilities. Both processes excel at producing smooth surfaces, intricate details, and transparent components that require minimal post-processing. These technologies are ideal for applications demanding visual fidelity, dimensional accuracy, and complex geometries with undercuts or internal channels.
Achieve exceptional surface finish with sub-100 µm layer heights, ideal for visual prototypes, medical models, and precision assemblies requiring tight tolerances. Access specialized material formulations including rigid, flexible, transparent, and biocompatible resins validated against ISO 10993 and USP Class VI standards. Leverage advanced post-processing including UV curing, clear coating, and pressure dyeing to enhance mechanical properties and aesthetic presentation.
Ultra-high resolution resin parts with smooth surface finish and exceptional detail. This technology operates with build volumes up to 1500 × 750 × 550 mm, achieving layer heights from 0.025 - 0.150 mm and maintaining tolerances of ±0.25% (Standard) / ±0.4% (Large parts).
Multi-material 3D printing with exceptional detail resolution and the ability to combine rigid, flexible, and transparent materials in a single build. This technology operates with build volumes up to 380 × 284 × 380 mm, achieving layer heights from 0.028 mm and maintaining tolerances of ±0.2% (Lower limit of ±0.2 mm).
Both SLA (Stereolithography) and PolyJet cure liquid photopolymer resins to create high-detail parts with smooth surfaces. SLA uses a laser to cure resin in a vat, while PolyJet jets droplets of photopolymer that are instantly UV-cured. Each technology excels in different detail, material, and application requirements.
Note: Choose SLA for high-detail single-material parts with excellent surface finish and cost efficiency. Choose PolyJet when you need multi-material capabilities, overmolded assemblies, or parts requiring rigid and flexible materials in a single build.
Metal powder bed fusion uses high-powered lasers to selectively fuse or melt metal powder layer by layer, creating fully dense metal parts with mechanical properties matching or exceeding traditionally manufactured components. DMLS (Direct Metal Laser Sintering) and SLM (Selective Laser Melting) both operate in controlled inert atmospheres to prevent oxidation, enabling the production of complex geometries impossible with conventional machining. These processes support aerospace-grade materials including titanium, stainless steel, aluminum, and Inconel for flight-critical hardware, medical implants, and high-performance industrial components. Integrated post-processing including stress relief, HIP, and CNC machining delivers production-ready parts with complete material traceability.
Manufacture fully dense metal parts from certified aerospace and medical-grade alloys with documented material properties and full traceability through AS9100-compliant workflows. Enable design optimization including topology-optimized structures, conformal cooling channels, and integrated assemblies that consolidate multiple components into single prints. Access complete post-processing capabilities including heat treatment, hot isostatic pressing (HIP), precision CNC machining, and dimensional inspection for end-use certification.
Fully dense, high-performance metal parts with exceptional strength for aerospace, automotive, and medical applications. This technology operates with build volumes up to 380 × 284 × 380 mm, achieving layer heights from 0.02 - 0.06 mm and maintaining tolerances of ±0.2mm to ±0.5mm (Size dependent).
Complete powder melting for ultra-high density metal parts with superior mechanical properties and fine surface detail. This technology operates with build volumes up to 250 × 250 × 325 mm, achieving layer heights from 0.02 - 0.05 mm and maintaining tolerances of ±0.1mm to ±0.3mm (Feature dependent).
Both DMLS (Direct Metal Laser Sintering) and SLM (Selective Laser Melting) use lasers to fuse metal powder layer by layer. The key difference: DMLS sinters powder particles at a molecular level, while SLM completely melts the powder creating a homogeneous melt pool. This fundamental difference affects density, mechanical properties, and optimal applications.
Note: Choose DMLS for proven industrial applications requiring strong, functional metal parts with excellent cost-to-performance ratio. Choose SLM when maximum density, fatigue resistance, and material properties are critical—particularly for aerospace, medical implants, and high-performance applications.
5-axis CNC machining bridges additive finishes with tight tolerances, superior surface finish, and rapid turnaround.
Ideal for machined NPI parts, tooling, and secondary ops on additive builds. Handles aerospace alloys, engineering plastics, and composites with ease. In-process inspection and metrology maintain PPAP, FAIR, and AS9100 compliance.
Precision subtractive manufacturing for high-tolerance parts across metals and advanced engineering polymers. Multi-axis CNC milling, turning, and finishing deliver production-grade components with repeatable quality. This technology operates with build volumes up to 1000 x 600 x 500 mm, achieving layer heights from N/A and maintaining tolerances of +/- 0.020 mm achievable (material and geometry dependent).
Every technology is backed by process design guides, finishing recipes, and compliance packets. Start with the most-requested downloads below or connect with engineering for program-specific documentation.
Our Selective Laser Sintering (SLS) design guidelines help engineers and designers improve part quality, lower costs, and speed up production. Whether for prototypes or end-use parts, these best practices ensure strong, accurate SLS components with excellent surface finish and dimensional stability.
Our design guidelines for Stereolithography (SLA) include important information to improve part quality, minimize costs, and reduce overall manufacturing time. By following the guidelines, you can produce high-quality parts, reduce expenses, and improve productivity.
Our design guidelines for MJF include important information to improve part quality, minimize costs, and reduce overall manufacturing time. By following the guidelines, you can produce high-quality parts, reduce expenses, and improve productivity.
AS9100 and ISO 9001 quality documentation, PPAP, FAIR, and C of C templates ready to pair with your build.
Share tolerances, surface finish targets, and production volumes with our engineering team. We will recommend the best-fit technology, material, and inspection plan within one business day.