Direct Metal Laser Sintering

Direct Metal Laser Sintering (DMLS) icon

Direct Metal Laser Sintering (DMLS) uses a precise, high-wattage laser to micro-weld powdered metals and alloys to form fully functional metal components from your CAD data. DMLS eliminates time-consuming tooling, and creates complex geometries not possible with other metal manufacturing processes. Made from materials like Inconel, Aluminum, Stainless Steel, and Titanium, DMLS parts are strong, durable, and heat-resistant. DMLS parts are also denser than investment casted metal parts. This accurate metal 3D printing process provides fine feature detail, making it ideal for complex oil and gas components, custom medical guides, consolidated aerospace parts, and tough functional prototypes.

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Benefits of DMLS

Design Freedom

Build real metal parts without conventional manufacturing limitations. With DMLS, you can create durable, intricate metal parts that until now, were difficult or impossible to fabricate with other manufacturing processes.

Streamlined Manufacturing

Consolidate design and optimize value. As a 3D printing technology, DMLS allows you to integrate multiple components – such as mountings, fasteners, and sectioned parts – into a single, strong metal part. This reduces weight, cuts down waste, and saves the time and resources needed for assembly.

Functional Parts, Fast

Cut lead times and get results. From prototypes to low-volume production parts, DMLS can accelerate your project’s design and manufacturing timeline. Build tough, hard-working prototypes to test components in real-world applications, and eliminate time-consuming tooling for low-volume production parts.


Raw parts have a surface finish comparable to a fine investment cast part, but expert finishing services are crucial for a successful end-use component. This is partly why DMLS is not feasible for many companies and firms to take in-house with their own 3D printing operations, but Stratasys Direct Manufacturing has the resources and experience you need. We offer a variety of professional finishing options, such as media blasting, electroplating, polishing, and CNC machining. Parts can also be heat treated in order to maximize mechanical properties.

DMLS Applications

DMLS is a great solution for complex metal parts you can’t build with conventional manufacturing technologies.

3D printed metal part
  • Common applications include:
  • Parts with cavities, undercuts, draft angles
  • Fit, form, and function models
  • Tooling, fixtures, and jigs
  • Conformal cooling channels
  • Rotors and impellers
  • Complex bracketing


Revolutionary DMLS Surgical Tool Repairs Ligaments

Dr. Piasecki set out to improve the success rate of ACL reconstruction by modifying the standard surgical technique using a 3D printed metal surgical tool.


DMLS Materials

DMLS’s additive metals and alloys are used for dense, corrosive resistant, and high-strength parts, which can be further treated through heat, stress relief, coating, and sterilization.


DMLS: Frequently Asked Questions

Are DMLS parts as strong as traditionally manufactured metal components?
Yes. The parts created with DMLS have mechanical properties equivalent to a cast metal part. Detailed information can be found in the DMLS materials page.
What is the porosity of DMLS parts?
DMLS parts can reach a 99.5% density. In fact, 3D printed metals are above industry standards for density testing.
What level of detail can be obtained with DMLS?
DMLS is available in several resolutions. At its highest resolution, the layer thickness is 0.0008” – 0.0015” Z and the X/Y resolution is 0.012” – 0.016”. The minimum hole diameter is 0.035” – 0.045”. Read the DMLS design guidelines to learn more.

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