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DMLS in Aluminum, Inconel or Titanium – Is it worth it?

DMLS Materials


Since DMLS is an additive technology, it drastically reduces material waste in comparison with traditional processes. Investment casting of titanium is difficult and often has a high scrap rate. Currently, many titanium aerospace components are machined from solid stock, often cutting away 90% or more of the original material. This becomes a time consuming, costly operation that can be completely eliminated by using titanium DMLS.

Some of the characteristics that make titanium ideal for aerospace applications also make it difficult to machine. Its hardness and low heat conductivity reduce tool speeds and life, require a great deal of liquid cooling during machining, which can limit the productivity of certain shapes that usethin walls. Laser-sintered titanium retains the beneficial properties of the metal and involves no tool-wear or coolant costs. In addition, nearly any geometry, including thin walls, can be created with laser-sintering.

Typical Applications:

  • Direct manufacture of functional prototypes, small series products, individualized products
  • Spare parts requiring good corrosion resistance properties
  • Parts requiring a combination of high mechanical properties and low specific weight
  • Structural and engine components for aerospace and motor racing applications


EOS Aluminum AlSi10Mg is a master alloy aluminum powder. AlSi10Mg is a typical casting alloy with good casting properties especially for parts with thin walls and complex geometries. The alloy combination silicon/magnesium results in a significant increase in the strength and hardness. It also features good dynamic properties and is therefore used for parts subject to high loads.

Parts made of EOS Aluminum AlSi10Mg can be machined, wire-eroded and electrical discharge machined, welded, micro-blasted, polished and coated. Standard building parameters completely melt the powder in the entire partwhile unexposed powder can be reused.

Typical Applications:

  • Direct manufacture of functional prototypes, small production runs, user-specific products or spare parts
  • Parts that require a combination of good thermal properties with low weight


This material is ideal for many high temperature applications such as gas turbine parts, instrumentation parts, power and process industry parts. Material also possesses excellent cryogenic properties and potential for cryogenic applications. Using this material allows you to produce parts quickly, while still being affordable.

Standard processing parameters use full melting of the entire geometry, typically with 20 µm layer thickness. Parts built from EOS Nickel Alloy IN718 can be easily post-hardened to 40-47 HRC (370-450HB) by precipitation-hardening heat treatments. In both as-built and age hardened states the parts can be machined, spark-eroded, welded, micro shot-peened, polished and coated, if required. Unexposed powder can be reused.

Typical Applications:

  • Aero and land-based turbine engine parts
  • Rocket and space application components
  • Chemical and process industry parts
  • Oil well, petroleum and natural gas industry parts

Comprehensive Capabilities for Rapid Manufacturing

At Fathom we offer a unique advantage of speed and agility-our experts help companies go from concept to prototype to manufacturing in ways not previously possible. 

3D Printing / Additive Manufacturing
90+ Machines  
SLS / / Two-day  SLA / / Next-day 
FDM / / Next-day DMLS / / Three-day 
PolyJet / / Same-day MJF / / Two-day
Injection Molding

30 Second Quotes

Prototype Tool / / As soon as 10 days

10K Parts / / 10 days

Production Tool / / As soon as 3 weeks

CNC Machining

3 & 5 Axis Milling & Turning
(Plastics, Composites and Metals)

Tolerance Accuracy Range
from +/-0.001″ to 0.005″

Urethane Casting

Injection Molding Adjacent
without High Costs of Metal Tools

Most Commonly Used for High-Volume
Prototyping & Bridge to Production

Let’s get started.

Fathom is driven by advanced technologies and methods that enhance and accelerate today’s product development and production processes.