DMLS Production
DMLS (Direct Metal Laser Sintering) was invented by EOS GmbH in 1987 and remains the most qualified metal additive manufacturing process for aerospace and medical applications. A 200–400W Yb:fiber laser sinters pre-alloyed powder layer by layer (20–100 µm) to produce 99.5% dense parts. Six alloys certified across aerospace (AMS 4999, AS9100D) and medical (ASTM F136, ISO 13485) standards.
Process Engineering
Process engineering for DMLS covers laser power, scan speed, hatch spacing, and layer thickness optimization for energy density targeting (50–100 J/mm³). Support strategy balances residual stress management against post-processing cost. First-article inspection includes CMM dimensional verification, Archimedes density measurement, and mechanical testing per specification.
Post-Processing
DMLS post-processing chain for aerospace production: stress relief (mandatory for all structural parts) → HIP at 900°C/100 MPa (fatigue-critical) → CNC machining on datum surfaces and fits → non-destructive evaluation (X-ray CT, dye penetrant, ultrasonic). Full traceability to raw material lot certificates maintained per AS9100D.
Material Qualification
Qualifying a new DMLS alloy or platform requires process parameter development, mechanical testing at multiple orientations (XY, XZ, Z), density measurement, and comparison against wrought baseline. We cover the qualification protocol, powder specification requirements (chemistry, PSD, flowability), and the testing matrix needed for AS9100D or FDA design validation packages.