Direct Metal Laser Sintering is a metal additive manufacturing process that uses a high-power laser to selectively melt and fuse metallic powder particles layer by layer. The term was trademarked by EOS GmbH but is often used generically for laser powder bed fusion of metals.

DMLS and Selective Laser Melting (SLM) are often used interchangeably, though technically DMLS historically referred to partial melting while SLM implies full melting. Modern systems typically achieve full melting.

Key characteristics:

• High resolution suitable for complex geometries and internal channels
• Support structures required for overhangs
• Post-processing includes support removal, stress relief, and often HIP
• Common materials: Ti-6Al-4V, Inconel 718, AlSi10Mg, 316L stainless steel

• Layer Thickness 20-60 µm
• Laser Power 200-1000W (varies by system)
• Build Rate 5-20 cm³/hour
• Minimum Feature Size ~0.1-0.2 mm

• Powder Bed Fusion
• Selective Laser Melting
• Electron Beam Melting