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DMLS - Direct Metal Laser Sintering

GPI Prototype is a service provider of Direct Metal Laser Sintering (DMLS), also known as direct metal laser melting (DMLM). As one of the first DMLS service providers in the country, GPI produces metal parts for applications ranging from prototypes to production. DMLS technology is ideal for a variety of applications including the creation of conformal cooling channels for injection molding tooling.

Utilizing the DMLS process, metal parts of the most complex geometries are built layer-by-layer (down to 20 microns) directly from 3D CAD data. Parts built using DMLS have excellent mechanical properties equivalent to wrought materials, high detail resolution, and exceptional surface quality. The metal powder is melted entirely to create a fully dense, fine, homogenous structure. Unique geometric freedom of design enables DMLS to form cavities and undercuts, which with conventional machining methods, can only be produced with great difficulty, if at all.

Additionally, when a part needs to be tested and re-designed over and over, the lead time for receiving a traditionally tooled part can create a large bottleneck in the final production process. DMLS produces parts that are extremely high quality and can be built in a matter of hours or days rather than weeks. The ability to generate functional metal prototypes in short order radically impacts design processes, accelerating design cycles and time to market.

Depending on size and geometries, in some cases the turnaround time for a part can be as little as a few hours. Furthermore, these parts can undergo functional testing in the environment for which they were designed. This technology delivers unlimited potential for engineers to create previously impossible solutions, embracing a new era of design-driven manufacturing.



GPI Prototype currently has six DMLS machines at our Lake Bluff, IL facility. There are five machines from EOS including two EOSINT M 270 machines, two EOSINT M 280 machines, and one EOSINT M 290. We also have one ProX 300 direct metal printer from 3D Systems.


DMLS MATERIALS: Click on the material type to view a data sheet.

Material Characteristics Advantages / Applications

Stainless Steel (PH1)

• 15-5 Mechanical Properties
• 20 or 40 Micron Layers
• 30-35 HRC Built
• Post Hardened to 40 HRC

• Prototype / Production Parts
• High Toughness, Ductility, Strength

Stainless Steel (GP1)

• 17-4 Mechanical Properties
• 20 or 40 Micron Layers
• 250-400 HV Hardness
• Post Hardenable

• Prototype / Production Parts
• Good Mechanical Properties

Cobalt Chrome (MP1)

• High Carbon CoCr Alloy
• 20 or 40 Micron Layers
• 35-45 HRC Built

• Turbines & Engine Parts
• High Temperature Resistance

Maraging Steel (MS1) - Tooling Steel

• Maraging (Tooling) Steel
• 20 or 40 Micron Layers
• 33-37 HRC Built
• Post Hardened to 50-54 HRC

• Injection Molding Tooling
• Conformal Cooling Channels
• Easily Machinable & Excellent Polishability

Titanium Alloy Ti-64

• Pre-Alloyed Ti6AlV4
• 30 Micron Layers
• 41-44 HRC Built

• Aerospace Parts
• High Strength & Light Weight

Aluminium AlSi10Mg

• Good Strength & Hardness
• Low Weight
• Good Thermal Properties

• Low Weight Applications
• Automotive & Racing Applications
• Thermal Parts

NickelAlloy IN718

• Nickel Based Heat Resistant Alloy
• 20 Micron Layers
• 30 HRC Built
• Post Hardened 47 HRC

• Turbine Engines
• Rocket & Aerospace Applications
• Chemical Industry Parts
• Heat & Corrosion Resistant


From left to right: Raw Finish, Shot Peen, Shot Blast, Mirror Polish, Medium Polish, Brush Finish




Filename Size
An Adobe Acrobat file Case Study - SEDS at UCSD DMLS Rocket Engine 2.02 MB
An Adobe Acrobat file DMLS Design Rules 1.05 MB
An Adobe Acrobat file EOSINT M 270 Brochure 88.99 KB
An Adobe Acrobat file EOSINT M 280 Brochure 1.7 MB
An Adobe Acrobat file Finishing Options for Direct Metal Laser Sintering (DMLS) 305.35 KB
An Adobe Acrobat file Whitepaper - Mechanical Testing of DMLS Parts 1.6 MB
An Adobe Acrobat file Whitepaper - Optimised Mould Temperature Control Procedure Using DMLS 519.35 KB

If you are looking for fast metal parts with excellent mechanical properties, high resolution and exceptional surface quality, please give us the opportunity to quote your next project.

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