Manufacturing services · Chapter F · Method 38

Direct metal laser sintering (DMLS)

A laser melts fine metal powder layer by layer in an inert atmosphere, producing dense metal parts with internal channels and lattices.

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Metal parts emerging from the powder bed after a DMLS build. Representative process photo · René Volfík · CC BY-SA 4.0 · Wikimedia Commons

How it works

Direct metal laser sintering (DMLS), step by step.

A labelled schematic of the process (not to scale), and the four steps every job goes through.

Labelled diagram showing how direct metal laser sintering (dmls) works — Schematic · not to scale. Drawn by TCI Group.

STEP 01

Spread

A recoater spreads metal powder.

STEP 02

Melt

The laser melts each cross-section.

STEP 03

Stress relieve

Heat treat on the build plate.

STEP 04

Remove & finish

Cut from plate, remove supports, machine.

Reference figures

What to expect.

Typical industry values to help you plan. We agree the figures for your part on the drawing.

Tolerance±0.13 mm + 0.002 mm/mmTypical

FinishRa 5–25 µmOrientation dependent

Min Feature~0.5 mmPositive features

DensityNear fullFully dense metal

Materials	Stainless 316L and 17-4PH, aluminium AlSi10Mg, titanium Ti6Al4V, Inconel 625/718, maraging steel.
Finishes	Rough as built; bead blasted, machined, polished or heat treated.
Design guidance	Self-supporting angles above about 45°. Add machining stock on critical faces. Use conformal cooling channels in mould inserts.
Best suited to	Conformal-cooled mould inserts, aerospace brackets, manifolds and medical parts.
Watch-outs	High cost per part; flatness and threads usually need machining.

Other methods in 3D printing

Previous: Carbon DLS Next: Metal binder jetting

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Reference figures are typical published industry values for planning, not a guarantee; final tolerances, materials and finishes are agreed in writing for each project.