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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. The aerospace industry relies on titanium due to its strength, low-weight and high mechanical properties. 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 and require a great deal of liquid cooling during machining. This can limit the productivity of certain shapes that use thin walls. Laser-sintered titanium retains the beneficial properties of the metal and involves no tool-wear or coolant costs. Nearly any geometry, including thin walls, can be created with laser-sintering.

Typical Applications //

  • Direct Manufacture of Functional Prototypes
  • Spare Part Replacement
  • Parts With High Mechanical Properties & Low Weight
  • Structural & Engine Components for Aerospace & Racing


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 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
  • Spare Part Replacement
  • Parts With Good Thermal Properties & 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 & Land-Based Turbine Engine Parts
  • Rocket & Space Application Components
  • Chemical & Process Industry Parts
  • Oil Well, Petroleum & Natural Gas Industry Parts

DMLS 3D Printing Quote 

Using Fathom for your AM project is easy. Fathom utilizes a state-of-the-art, on-demand online platform that provides our clients with unlimited access to quotes and orders for prototyping and production parts. Our production team is ready to meet your needs with a wide range of material options. Fathom also offers advanced and expedited services. Companies of all sizes trust us from medical to consumer products, electronics, automotive, aerospace and more, including 9 of the Top 10 Fortune 500 Companies. Receive fast DMLS quotes and quick turnaround on parts through Fathom’s SmartQuote platform. 


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. 

90+ Machines  
SLS / / Two-day  SLA / / Next-day 
FDM / / Next-day DMLS / / Three-day 
PolyJet / / Same-day MJF / / Two-day

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Prototype Tool / / As soon as 10 days
10K Parts / / 10 days
Production Tool / / As soon as 3 weeks

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

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

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Injection Molding Adjacent
without High Costs of Metal Tools

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

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Finishing, Production Painting and Color Matching

Assembling, Including Embedded Electronic
Components, Threaded Inserts, and More

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CAD, DFAM and DFM Services

Apply Methods to Increase Speed
and Decrease Total Cost

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Highly Trained Staff / / Full-Time & Part-Time
Support as Short-Term & Long-Term Strategy

Decrease Downtime with Customizable
Staffing Accelerates Implementation

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