The size limitations of DMLS printed parts are primarily dictated by the size of the printing chamber in the DMLS machine which vary by material.

Aluminum (AlSi10Mg) - 400mm x 300mm x 400mm (15.75" x 11.81" x 15.75")
Stainless Steel (316L) - 280mm x 280mm x 350mm (11.02" x 11.02" x 13.78")
Titanium (TC4) - 150mm x 150mm x 200mm (5.91" x 5.91" x 7.87")

Parts that exceed the build chamber size, the design can sometimes be split and welded together.

There is also a practical minimum size for DMLS parts, determined by the ability to handle and process the part without damage. This minimum size is often a few millimeters in each dimension.

DMLS is known for its high precision and accuracy, which makes it suitable for complex, high-tolerance parts such as those used in aerospace, automotive, and medical industries.

Accuracy and Tolerance: The typical dimensional accuracy of DMLS can be within ± 0.3% of the nominal size. However, the actual accuracy can depend on several factors, including part geometry, size, and the specific material used.  The layer thickness in DMLS typically ranges from 20 to 60 micrometers, which contributes to the precision of the process in capturing fine details.

Achieving the best accuracy and precision with DMLS requires careful design, orientation, and processing. Post-processing can also play a significant role in achieving the desired tolerances and surface finishes.

Yes, DMLS parts often undergo various post-processing techniques to improve their mechanical properties, surface finish, and dimensional accuracy. Common post-processing methods include:

• Heat Treatment: To relieve internal stresses and improve mechanical properties, parts can be heat-treated. Processes like annealing, hardening, and aging are commonly used.

• Surface Finishing: To achieve smoother surfaces, techniques such as sandblasting, tumbling, polishing, and machining are employed.

• Support Removal: Supports used during printing are removed, usually through manual methods or CNC machining.

• Machining: For achieving tighter tolerances or specific features, CNC machining is often used as a secondary process.

• Coating: Surface coatings can be applied for aesthetic purposes or to enhance properties like corrosion resistance.

Each of these post-processing steps can significantly enhance the quality and functionality of DMLS printed parts, making them suitable for a wide range of high-performance applications.

DMLS is widely used across various industries due to its ability to create complex geometries and high-strength parts from metal. Some typical applications include:

• Aerospace: In the aerospace industry, DMLS is used for producing lightweight, high-strength components such as turbine blades, fuel nozzles, and brackets. The technology is valued for its ability to create parts that withstand high temperatures and stresses.

• Automotive: The automotive sector utilizes DMLS for creating custom, lightweight parts, including engine components, transmission parts, and other complex assemblies.

• Medical: DMLS is extensively used in medical applications, especially for creating custom implants, orthopedic devices, and surgical instruments. The technology's ability to produce biocompatible, patient-specific geometries is highly valued.

• Dental: In dental applications, DMLS is used for creating crowns, bridges, and orthodontic devices with a high level of precision.

• Tooling and Molds: DMLS is also used for producing tooling and mold inserts with complex internal cooling channels, which can significantly improve the efficiency of injection molding processes.

• Research and Development: Due to its flexibility in producing complex shapes, DMLS is a popular choice in R&D sectors for prototyping and testing new designs.

Yes, one of the key advantages of DMLS is its ability to produce parts with complex internal structures and intricate geometries that would be difficult or impossible to create using traditional manufacturing methods. This includes:

• Internal Channels and Cavities: DMLS can create parts with internal channels and cavities for applications like lightweight structures, cooling channels in mold tools, and lattice structures for medical implants.

• Complex Geometries: The technology excels in fabricating geometrically complex parts without the need for assembly. This includes intricate honeycomb structures, complex conformal cooling channels, and detailed mechanical components.

• Customized Designs: DMLS allows for the customization of parts, such as patient-specific medical implants with porous structures that encourage bone growth.