Metal 3D Printing Service

Get quality metal 3D-printed prototypes and production parts. Request an online quote today.

Certifications ISO 9001:2015 | AS9100D | ITAR

Jump to Section

→ Capabilities
→ Compare Material Properties
→ Material Options
→ Post-Processing
→ Why Metal 3D Printing?

Direct metal laser sintering (DMLS) is an industrial metal 3D printing process that builds fully functional metal prototypes and production parts in 7 days or less. A range of metals produce final parts that can be used for end-use applications.

Metal 3D printing technology is commonly used for:

Prototyping in production-grade materials
Complex geometries
Functional, end-use parts
Reducing metal components in an assembly

metal 3d printed part with internal channels

We hope you find this guide helpful. If the file did not download, you can find it here.

Metal 3D Printing Guide

Jump start your metal 3D printing with this guide that covers material selection, design, post-processing, and quality inspections.

I agree to receive email messages containing service updates and Design Tips from Protolabs and its affiliates

Metal 3D Printing Capabilities

Our basic guidelines for metal 3D printing include important design considerations to help improve part manufacturability, enhance cosmetic appearance, and reduce overall production time.

Max Dimensions
Layer Thickness
Minimum Feature Size
Tolerances
Surface Finishes

	US	Metric
Normal Resolution	9.6 in. x 9.6 in. x 13.0 in.	245mm x 245mm x 330mm
Normal Resolution (X Line*)	31.5 in. x 15.7 in. x 19.7 in.	400mm x 800mm x 500mm
High Resolution	3.5 in. x 3.5 in. x 2.7 in. Al: 3.8 in. x 3.8 in. x 3.7 in.	88mm x 88mm x 70mm Al: 98mm x 98mm x 94mm

*At this time, Inconel 718 and Aluminum are the only materials available on our large format, X Line machine

	US	Metric
Normal Resolution	0.0012 in.	30 microns
Normal Resolution (X Line*)	Inconel: 0.00236 in. Aluminum: 0.00157 in.	Inconel: 60 microns Aluminum: 40 microns
High Resolution	0.00079 in.	20 microns

*At this time, Inconel 718 and Aluminum are the only materials available on our large format, X Line machine

	US	Metric
Normal Resolution	0.015 in (0.030 in. for Aluminum)	0.381mm (0.762mm for Aluminum)
Normal Resolution (X Line*)	0.015 in. (0.030 in. for Aluminum)	0.381mm (0.762mm for Aluminum)
High Resolution	0.006 in. Aluminum: 0.015 in.	0.153mm Aluminum: 0.381mm

*At this time, Inconel 718 and Aluminum are the only materials available on our large format, X Line machine

Metal 3D Printing Tolerances

For well-designed parts, tolerances in the X/Y dimension of ±0.003 in. (0.075mm) for first inch plus 0.1% of nominal length. (0.001mm/mm), and Z dimension tolerances of ±0.006 in. for first inch plus 0.1% of nominal length, can typically be achieved. Note that tolerances may change depending on part geometry.

*At this time, Inconel 718 and Aluminum are the only materials available on our large format, X Line machine

Finishing Option	Description
Standard	Support structures are removed and layer lines are visible.
Brushed	Indicated surfaces will be directionally sanded to desired grit level.
Satin	Indicated surfaces will be sanded to desired grit level, grit blasted and then bead blasted.
Polished	Indicated surfaces will be sanded to desired grit level. Surfaces will be somewhat reflective and bright, but some sanding lines or marks may still be visible.

Max Dimensions

expand_less expand_more

Layer Thickness

expand_less expand_more

Minimum Feature Size

expand_less expand_more

Tolerances

expand_less expand_more

Surface Finishes

expand_less expand_more

chevron_left

chevron_right

Materials	Resolution	Condition	Ultimate Tensile Strength (ksi)	Yield Stress (ksi)	Elongation (%)	Hardness
Stainless Steel (17-4 PH)	20 μm	Solution & Aged (H900)	199	178	10	42 HRC
Stainless Steel (17-4 PH)	30 μm	Solution & Aged (H900)	198	179	13	42 HRC
Stainless Steel (316L)	20 μm	Stress Relieved	82	56	78	90 HRB
Stainless Steel (316L)	30 μm	Stress Relieved	85	55	75	88 HRB
Aluminum (AlSi10Mg)	20 μm	Stress Relieved	39	26	15	42 HRB
	30 μm	Stress Relieved	50	33	8	59 HRB
	40 μm	Stress Relieved	43	27	10	50 HRB
Cobalt Chrome (Co28Cr6Mo)	20 μm	As Built	182	112	17	39 HRC
Cobalt Chrome (Co28Cr6Mo)	30 μm	As Built	176	119	14	38 HRC
Inconel 718	20 μm	Stress Relieved	143	98	36	33 HRC
	30 μm	Stress Relieved	144	91	39	30 HRC
	30 μm	Solution & Aged per AMS 5663	208	175	18	46 HRC
	60 μm	Stress Relieved	139	83	40	27 HRC
	60 μm	Solution & Aged per AMS 5663	201	174	19	45 HRC
Titanium (Ti6Al4V)	20 μm	Stress Relieved	153	138	15	35 HRC
Titanium (Ti6Al4V)	30 μm	Stress Relieved	144	124	18	33 HRC

20 μm = high resolution (HR)

30, 40, and 60 μm = normal resolution (NR)

Materials	Resolution	Condition	Ultimate Tensile Strength (MPa)	Yield Stress (MPa)	Elongation (%)	Hardness
Stainless Steel (17-4 PH)	20 μm	Solution & Aged (H900)	1,372	1,227	10	42 HRC
Stainless Steel (17-4 PH)	30 μm	Solution & Aged (H900)	1,365	1,234	13	42 HRC
Stainless Steel (316L)	20 μm	Stress Relieved	565	386	78	90 HRB
Stainless Steel (316L)	30 μm	Stress Relieved	586	379	75	88 HRB
Aluminum (AlSi10Mg)	20 μm	Stress Relieved	268	180	15	46 HRB
	30 μm	Stress Relieved	345	228	8	59 HRB
	40 μm	Stress Relieved	296	186	10	50 HRB
Cobalt Chrome (Co28Cr6Mo)	20 μm	As Built	1255	772	17	39 HRC
Cobalt Chrome (Co28Cr6Mo)	30 μm	As Built	1213	820	14	38 HRC
Copper (CuNi2SiCr)	20 μm	Precipitation Hardened	496	434	23	87 HRB
Inconel 718	20 μm	Stress Relieved	986	676	36	33 HRC
	30 μm	Stress Relieved	993	627	39	30 HRC
	30 μm	Solution & Aged per AMS 5663	1434	1207	18	46 HRC
	60 μm	Stress Relieved	958	572	40	27 HRC
	60 μm	Solution & Aged per AMS 5663	1386	1200	19	45 HRC
Titanium (Ti6Al4V)	20 μm	Stress Relieved	1055	951	15	35 HRC
Titanium (Ti6Al4V)	30 μm	Stress Relieved	993	855	18	33 HRC

20 μm = high resolution (HR)

30, 40, and 60 μm = normal resolution (NR)

These figures are approximate and dependent on a number of factors, including but not limited to, machine and process parameters. The information provided is therefore not binding and not deemed to be certified. When performance is critical, also consider independent lab testing of additive materials or final parts.

Metal 3D Printing Material Options

Below is our available metal alloys for 3D printing. Various heat treatments are available depending on material.

Stainless Steel (17-4 PH)

Stainless Steel 17-4 PH is a precipitation hardened stainless steel that is known for its hardness and corrosion resistance. If needing a stainless steel option, select 17-4 PH for its significantly higher tensile strength and yield strength, but recognize that it has far less elongation at break than 316L. Final parts built 17-4 PH receive vacuum solution heat treatment as well as H900 aging.

Primary Benefits

Heat treated for full hardness and strength
Corrosion resistance

Learn More

Finishing Options

Standard

Brushed 150

Brushed 220

Brushed 400

Satin

Polished

Stainless Steel (316L)

Choose 316L when stainless steel flexibility is needed; 316L is a more malleable material compared to 17-4 PH. Final parts built in 316L receive stress relief application.

Primary Benefits

Heat treated for full hardness and strength
Corrosion resistance

Learn More

Finishing Options

Standard

Brushed 150

Brushed 220

Brushed 400

Satin

Polished

Aluminum (AlSi10Mg)

Aluminum (AlSi10Mg) is comparable to a 3000 series alloy that is used in casting and die casting processes. It has good strength -to-weight ratio, high temperature and corrosion resistance, and good fatigue, creep and rupture strength. AlSi10Mg also exhibits thermal and electrical conductivity properties. Final parts built in AlSi10Mg receive stress relief application.

Primary Benefits

High stiffness and strength relative to weight
Thermal and electrical conductivity

Learn More

Custom Finishing Options

Standard

Brushed 150

Brushed 220

Brushed 400

Satin

Polished

Inconel 718

Inconel is a high strength, corrosion resistant nickel chromium superalloy ideal for parts that will experience extreme temperatures and mechanical loading. Final parts built in Inconel 718 receive stress relief application. Solution and aging per AMS 5663 is also available to increase tensile strength and hardness.

Primary Benefits

Oxidation and corrosion resistance
High performance tensile, fatigue, creep, and rupture strength

Learn More

Custom Finishing Options

Standard

Brushed 150

Brushed 220

Satin

Cobalt Chrome (Co28Cr6Mo)

Cobalt Chrome (Co28Cr6Mo) is a superalloy comprised primarily of cobalt and chromium. It's high tensile strength and resistance to creep and corrosion makes it a good material choice for aerospace components and medical instrumentation.

Primary Benefits

High performance tensile and creep
Corrosion resistance

Learn More

Custom Finishing Options

Standard

Brushed 150

Brushed 220

Brushed 400

Satin

Polished

Titanium (Ti6Al4V)

Titanium (Ti6Al4V) is a workhorse alloy. When measured against Ti grade 23 annealed, the mechanical properties of Ti6Al4V are comparable to wrought titanium for tensile strength, elongation, and hardness.

Primary Benefits

High stiffness and strength relative to weight
High temperature and corrosion resistance

Learn More

Custom Finishing Options

Standard

Brushed 150

Brushed 220

Brushed 400

Satin

Polished

Post-Processing Capabilities for Metal 3D-Printed Parts

Improve strength, dimensional accuracy, and cosmetic appearance of final metal components with DMLS for production.

Surface Finishing

3- and 5-axis milling
Turning
Custom Finishing
- Brushed (150, 220, 400)
- Satin
- Polished
Passivation
Wire EDM
Tapping and reaming

Heat Treatments

Stress relief
NADCAP heat treatment
Hot isostatic pressing (HIP)
Solution annealing
Aging

Mechanical Testing

Tensile
Rockwell Hardness

Powder Analysis & Material

Traceability
Chemistry
Particle size and distribution analysis

Why Use Metal 3D Printing?

See how metal additive manufacturing technology can be used to reduce components within an assembly, fabricate complex geometries, and ultimately save you time and costs.

direct metal laser sintering process illustration

Click to enlarge

How Does Metal 3D Printing Work?

The DMLS machine begins sintering each layer—first the support structures to the base plate, then the part itself—with a laser aimed onto a bed of metallic powder. After a cross-section layer of powder is micro-welded, the build platform shifts down and a recoater blade moves across the platform to deposit the next layer of powder into an inert build chamber. The process is repeated layer by layer until the build is complete.

When the build finishes, an initial brushing is manually administered to parts to remove a majority of loose powder, followed by the appropriate heat-treat cycle while still fixtured in the support systems to relieve any stresses. Parts are removed from the platform and support structures are removed from the parts, then finished with any needed bead blasting and deburring. Final DMLS parts are near 100 percent dense.

Large Format Metal 3D Printing

Our large format 3D printers can build metal parts as large as 31.5 in. x 15.7 in. x 19.7 in. in Aluminum and Inconel. Large, 3D-printed parts are often used in industrial settings, aerospace applications, automotive, and energy.