
Direct Metal Laser Sintering (DMLS) 3D Printing
Complex Functional 3D Printed Metal Parts

What is Direct Metal Laser Sintering?

15" x 12"
Max X/Y Build Volume
± 0.3
MM Part Tolerances
4
Materials
8-12 Day
Average Lead Time
Metals| Direct Metal Laser Sintering

Stainless Steel 316L
Corrosion-Resistant Steel Alloy
316L Stainless Steel is produced using a powder bed tehnology known as direct metal laser sintering. 316L stainless steel is a widely used high-strength, high-hardness metal with excellent corrosion resistance ideal for automotive, industrial & aerospace applications.
Tensile Strength |
640 MPa |
Tensile Elongation |
40 % |
Tensile Modulus |
185 GPa |
Hardness |
89 HRB |
Relative Density |
100 % |

Aluminum AlSi10Mg
Lightweight Alloy
Aluminum AlSi10Mg is produced using a powder bed 3D Printing technology known as direct metal laser sintering. AlSi10Mg is widely used for light weight, thin wall parts for aerospace and automotive applications. AlSi10Mg offers fantastic machinability as well as good thermal and strength properties.
Tensile Strength |
379 MPa |
Tensile Elongation |
10 % |
Tensile Modulus |
68 GPa |
Hardness |
64 HRB |
Relative Density |
100 % |

Titanium Ti64
Corrosion Resistant Alloy
Titanium Ti64 is produced using powder bed 3D Printing technology known as direct metal laser sintering. Ti64 is widely used for high performance parts that require corrosion resistance and low specific weight and/or biocompatibility.
Tensile Strength |
1150 MPa |
Tensile Elongation |
11 % |
Tensile Modulus |
68 GPa |
Hardness |
400 HV |
Relative Density |
100 % |
Surface Finishes| Direct Metal Laser Sintering
Standard
Support structures removed and part is shot-peened to a uniform finish. Critical features are hand finishes. Surface roughness between 200-400 Ra
Custom
Critical features hand finishes and model is finished to a high aesthetic quality. High tolerance features machined to specification.
Direct Metal Laser Sintering | Applications
Learn How Major Industries Are Using Forge Labs
Aerospace
Automotive
Healthcare
Practical FX
Consumer Products
Design Guidelines | Direct Metal Laser Sintering
Direct Metal Laser Sintering (DMLS) is an additive manufacturing process that uses a bed of metal powder, fused together via a high powered laser. The laser fuses layers together by selectively scanning and hardening fine particles of metal powder to create a solid structure. After each cross section is sintered, the machine deposits another 40 um layer metal powder and the process repeats itself until the build is complete.
Direct Metal Laser Sintering is a complex manufacturing process that requires significant amount of post processing to remove the physical supports. These design guidelines covers specific design parameters, which will need to be followed to prevent build failures from occurring.
Optimizing your designs for Direct Metal laser Sintering will help keep manufacturing costs down. Price is primarily based upon the X, Y, & Z extents of your part with the biggest cost factor being how tall the part sits in the build. Small, dense or parts that nest low in the z-axis will be priced the most competitively in this technology. Wall thickness has a modest effect on the cost of the part, so it is important to avoid overly bulky or dense features.
Our DMLS machines have a building volume of: 400 x 400 x 400 mm (15.8 x 15.8 x 15.8 in) and a laser diameter of 100 um.
The throughput of Direct Metal Laser Sintering is limited, as parts can only be nested in the X & Y planes in the build chamber. This limits the amount of parts that can be built in a single run, making it more ideal for low volume manufacturing of small highly complex parts. Parts produced using DMLS are fully dense and provide a uniform finish with excellent mechanical properties, making it a suitable substitute to machining. Additional post-processing options are available to improve the surface finish or machine critical features to specification.
Minimum Wall Thickness
.8 mm
Engraved Details
Thickness & depth of at least 0.8 mm
Embossed Details
Thickness & depth of at least 0.7 mm
Clearance
0.5 mm
Minimum Hole Size
1.5 mm or 3 mm for internal chanels
Layer Height
40 μm
Maximum Build Size
400 x 400 x 400 mm (15.8 x 15.8 x 15.8 in)
Tolerances
±0.3%, with a lower limit of ±0.3 mm.
Surface Finish
Parts are shot peened to a surface roughness of 400 Ra
Warping & Deformities
Avoid large flat planes which are likely to cause warping.
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