Direct Metal Laser Sintering (DMLS) brings additive manufacturing’s design freedom to metal parts. For aerospace applications where every gram matters and every geometry must survive extreme conditions, DMLS is a game changer.
DMLS uses a high-power laser to selectively fuse metal powder particles layer by layer, building fully dense metal parts from a digital file. Materials include Inconel 718, Ti-6Al-4V, AlSi10Mg, and 316L stainless — all qualified for aerospace applications.
Traditional manufacturing often requires welding or bolting together multiple components. DMLS prints the equivalent assembly as a single monolithic part, eliminating joints (potential failure points), reducing weight, and simplifying supply chains. Turbine brackets that once required 14 parts and 6 weld operations can be produced as one DMLS component.
Topology optimisation removes material from low-stress zones. The resulting organic geometries are impossible to machine but straightforward to print. Aerospace brackets produced this way routinely achieve 30–50% weight reduction with equivalent or superior mechanical properties.