Direct Metal Laser Sintering | High-Strength Metal Parts
DMLS is a powder-bed fusion process designed for fully dense, high-performance metal components with complex internal geometries.
We manufacture functional metal parts for aerospace, medical, automotive, and industrial applications where strength, accuracy, and reliability are non-negotiable.
- Fully dense metal parts (≥99.5%)
- Complex internal channels & lattice structures
- No tooling required for low-volume production
- Production-grade alloys with material traceability
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What Is Direct Metal Laser Sintering?
Direct Metal Laser Sintering (DMLS) uses a high-powered fibre laser to fuse fine metal powder layer by layer inside a special gas that stops other gases from affecting the process.
DMLS is different from subtractive methods because it can produce geometries that can’t be machined. This includes things like internal cooling channels, conformal ducts and topology-optimised structures.
Key Characteristics of DMLS:
Near-wrought mechanical properties
Fine feature resolution
High dimensional accuracy
Excellent material utilization
DMLS is best suited for functional metal parts, not visual models.
Why Choose DMLS for Metal Parts?
| Engineering Requirement | How DMLS Delivers |
|---|---|
| High mechanical strength | Fully dense metal microstructure |
| Complex internal geometry | Freeform internal channels & lattices |
| Weight reduction | Topology optimization & lattice infill |
| Low-volume production | No tooling or molds required |
| Rapid iteration | Design changes without retooling |
Typical Lead Time: 7–15 business days
Typical Tolerance: ±0.1 mm (geometry dependent)
Start Your DMLS Project with Engineering Confidence
If your application demands high-strength metal parts with complex geometries, DMLS may be the right solution.
DMLS Material Options
All materials are supplied with full batch traceability and verified material data.
Common DMLS Materials:
AlSi10Mg – Lightweight, good thermal conductivity
316L Stainless Steel – Corrosion-resistant, medical & industrial use
17-4 PH Stainless Steel – High strength after heat treatment
Inconel 718 / 625 – High-temperature and fatigue resistance
Ti6Al4V (Grade 5) – Aerospace & medical-grade titanium
Material selection directly impacts strength, heat resistance, and post-processing requirements.
Baosheng Direct Metal Laser Sintering Capabilities
| Feature | Description |
| Build Size | 10″ x 10″ x 10″ (250 x 250 x 250 mm) |
| General Tolerances | +/- 0.005” for the first inch is typical, plus +/- 0.002” for every inch thereafter |
| Layer Height | .0012” – .0016″ depending on material |
| Surface Roughness | 150-400 µin Ra, depending on build orientation and material used for the build |
| Infill | 100% |
Design Guidelines for Reliable DMLS Parts
DMLS is not “print-and-go.” Proper design is critical.
Our engineers evaluate:
Support Strategy: Required for heat dissipation and stress control
Thermal Distortion Risk: Orientation and scan strategy optimization
Wall Thickness: Minimums based on alloy and geometry
Internal Channels: Powder removal and flow considerations
Post-Processing Needs: Stress relief, machining, surface finishing
Early engineering review prevents warping, cracking, and dimensional deviation.
When DMLS Is the Right Choice
Choose CNC Machining if:
Geometry is simple and volumes are high
Internal channels are not required
Choose DMLS if you need:
Complex internal features or conformal cooling
Lightweight, high-strength metal components
Low-volume or bridge production
Rapid iteration of functional metal parts
Choose Binder Jetting if:
High-volume production with secondary sintering is acceptable
Typical DMLS Applications
Where DMLS Excels
Aerospace brackets and structural components
Conformal cooling inserts for tooling
Medical implants and surgical instruments
Heat exchangers and fluid manifolds
High-performance automotive components
DMLS enables performance-driven designs, not just manufacturable ones.
What Affects DMLS Pricing?
Part volume and geometry complexity
Selected metal alloy
Support density and build orientation
Post-processing requirements (heat treatment, machining)
DMLS is not the lowest-cost option—but it often delivers the lowest total cost for complex, high-performance metal parts.
FAQs
Are DMLS parts fully dense?
Yes. Properly processed DMLS parts typically reach ≥99.5% density.
Do DMLS parts require post-processing?
Yes. Stress relief is mandatory; machining or surface finishing may be required depending on tolerance and application.
What file formats are preferred?
STEP is recommended. STL is accepted for reference.
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