Design Guidelines: Direct Metal Laser Sintering (DMLS)
Our basic guidelines for direct metal laser sintering include important design considerations to help improve part manufacturability, enhance cosmetic appearance, and reduce overall production time.
Size
Maximum Dimensions
| Normal Resolution | 9.6 in. x 9.6 in. x 13.0 in. |
|---|---|
| Normal Resolution (X Line*) | 31.5 in. x 15.7 in. x 19.7 in. |
| High Resolution | 3.5 in. x 3.5 in. x 2.7 in. |
| Normal Resolution | 245mm x 245mm x 330mm |
|---|---|
| Normal Resolution (X Line*) | 400mm x 800mm x 500mm |
| High Resolution | 88mm x 88mm x 70mm |
*These parts can only be built in Inconel 718
Accuracy
Layer Thickness
| Normal Resolution | 0.00118 in. |
|---|---|
| Normal Resolution (X Line) | 0.00236 in. |
| High Resolution | 0.00079 in. |
| Normal Resolution | 30 microns |
|---|---|
| Normal Resolution (X Line) | 60 microns |
| High Resolution | 20 microns |
Minimum Feature Size
| Normal Resolution | 0.015 in. |
|---|---|
| Normal Resolution (X Line) | 0.030 in. |
| High Resolution | 0.006 in. |
| Normal Resolution | 0.381mm |
|---|---|
| Normal Resolution (X Line) | 0.762mm |
| High Resolution | 0.153mm |
For well-designed parts, tolerances of ±0.003 in. (0.076mm) plus ±0.001 in./in. (0.001mm/mm) for each additional inch can typically be achieved. Note that tolerances may change depending on part geometry.
Design Essentials for 3D Printing
The 3D Printing Essentials reference guide offers guidelines and key considerations when designing for industrial 3D printing processes.
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3D Printing Surface Finish Guide
Download this quick reference guide that looks at all of your surface finish options across our six additive manufacturing technologies.
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Materials
- Aluminum / AlSi10Mg
- Cobalt Chrome
- Inconel 718
- Stainless Steel 17-4 PH
- Stainless Steel 316L
- Titanium / Ti 6-4
- Copper / CuNi2SiCr
Surface Finishes
| STANDARD | Expect roughness values of 200 to 400 µin Ra (0.005 to 0.010mm Ra), depending on material and resolution. |
|---|---|
| CUSTOM |
Secondary options include hand-polished or machined surfaces upon request. When tighter tolerances are required, we can provide secondary machining operations such as drilling, slotting, milling, and reaming. |
Production Capabilities
Improve strength, dimensional accuracy, and cosmetic appearance of final metal components with DMLS for production.
Post-Machining
- 3- and 5-axis milling
- Turning
- Wire EDM
- Tapping and reaming
Powder Analysis & Material
- Traceability
- Chemistry
- Particle size and distribution analysis
- Mechanical coupon testing
Mechanical Testing
- Tensile
- Rockwell Hardness
- Fatigue
- Vibration
Heat treatments
- Stress relief
- Hot isostatic pressing (HIP)
- Solution annealing
- Aging
Equipment
We use GE Additive Concept Laser Mlab, Mlab 200R, M2, and X Line 2000R machines for DMLS production that offer large build sizes, produce accurate parts, and provide quick turnaround times. The Mlab and Mlab 200R are ideal for manufacturing metal components with elaborate structures, and they are ideal when high surface quality and fine component structures are needed on parts. The M2 is a large platform machine that is able to produce larger metal parts than the Mlab, and the X Line 2000R can produce parts with build volumes as large as 800mm by 400mm by 500mm. All of our 3D printing equipment can handle both reactive and non-reactive metal powder.
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