DMLS & SLM Metal Additive Manufacturing
Metal 3D Printing Services
Metal 3D printing has evolved from prototyping to full-scale production. Using DMLS and SLM, we manufacture fully dense parts in titanium, aluminum, stainless steel, and nickel alloys — delivering complex geometries without tooling delays.
At Baetro, we do more than print. We review your CAD files for manufacturability, recommend the optimal material and process, and finish critical features on our CNC centers to hold ±0.001″ tolerances. Additive complexity meets subtractive precision — managed by one team.
±0.001″
After CNC finishing
3–7 days
Standard lead time
Free DFM
On every quote
MOQ 1
Prototype to production
Metal 3D Printing Fundamentals
What Is DMLS Metal 3D Printing?
DMLS, or direct metal laser sintering, is a powder bed fusion process that builds metal parts layer by layer. A high-power laser traces each cross-section of your CAD model across a bed of fine metal powder, selectively fusing particles together. The build platform lowers by 20–60 microns, a fresh layer of powder spreads across the bed, and the laser repeats the process. Over hundreds or thousands of layers, a fully solid metal part emerges from the powder.
SLM, or selective laser melting, works on the same principle but uses a higher-energy laser to fully melt the powder into a molten pool that solidifies into dense, metallurgically bonded layers. The practical difference matters for engineers choosing a process. At Baetro, we offer both DMLS and SLM, and recommend the right process after reviewing your design.
Layer-by-Layer Precision
20–60 micron layers controlled by high-power laser scanning
Complex Internal Geometries
Conformal cooling channels and lattice structures impossible to machine
DMLS & SLM Capability
Sintering and full melting options for alloys and pure metals
Zero Tooling Setup
No fixtures, no molds, no setup costs—print directly from CAD
Additive + Subtractive Manufacturing
Print complex near-net-shape geometry, then machine critical features to ±0.001 inches on our CNC centers.
Process Options
Our DMLS & SLM Capabilities
From standard powder bed fusion to hybrid additive-subtractive manufacturing, Baetro provides DMLS, SLM, and integrated CNC finishing for prototypes and production metal parts.
DMLS
Direct Metal Laser Sintering
DMLS uses a laser to sinter — partially melt and fuse — metal powder, achieving 95–98% density. It is historically the standard for tool steel, cobalt chrome, and maraging steel.
- Best for: tooling, medical prototypes, and complex alloy parts.
- Laser power: ~400W typical, gentler on certain alloys.
- Surface finish: Ra 10–20 μm as-printed.
SLM
Selective Laser Melting
SLM uses a higher-power laser to fully melt powder into a molten pool, achieving up to 99.9% density. Preferred for pure metals where maximum density matters.
- Best for: aerospace, high-stress end-use titanium and aluminum parts.
- Laser power: up to 1,000W for full melting.
- Surface finish: Ra 5–10 μm as-printed.
Hybrid manufacturing
DMLS + CNC Finishing
Print near-net-shape geometry on our DMLS/SLM machines, then finish critical bores, faces, and threads on our 5-axis CNC centers to hold ±0.001 inches.
- Best for: mating surfaces, press fits, and threaded holes.
- Industries: aerospace, medical, robotics, and precision hardware.
- Benefits: additive complexity with subtractive precision.
Procurement confidence
Why Choose Baetro for Metal 3D Printing?
Most metal 3D printing service bureaus print your part, remove supports, ship it, and hope you know what to do with the tolerances. At Baetro, we manage the full workflow under one roof.
Integrated CNC Post-Machining
We are one of the few manufacturers that combines industrial DMLS/SLM with precision CNC machining under one roof. Print your near-net-shape geometry, then let us machine critical bores, faces, and threads to ±0.001 inches. No shipping parts between vendors. No reconciling quality systems.
Instant Quotes & Transparent Pricing
Upload your CAD file and receive a quote in under 60 seconds. Our pricing engine calculates machine time, material volume, support structures, and post-processing to give you a fully loaded delivered cost — not a lowball as-printed number with surprises later.
Free DFM Feedback on Every Order
When you upload a CAD file, our engineers do not just price it. They review it for manufacturability. We flag wall thicknesses below 0.5 mm, unsupported overhangs, and features that would benefit from CNC finishing. We suggest orientation changes that reduce support volume by 20% or more.
ISO 9001 & AS9100 Certified Quality
Our Qingdao facility operates under ISO 9001 quality management systems, with AS9100 certification for aerospace work. Every part is inspected on CMM equipment, and we provide full inspection reports with every shipment. Material traceability certificates are available upon request.
No Minimum Order Quantity
Order one part or one hundred. There is no tooling investment, no setup fee, and no minimum order quantity. Our process, quality standards, and inspection routines are the same regardless of quantity.
Fast Lead Times & Documentation
Standard lead time is 3–7 days from order to shipment, with real-time order tracking so you know exactly where your parts are. Every shipment includes inspection reports, material certifications, and required documents.
Material library
Materials We Print
We offer fully dense metal powders across aluminum, stainless steel, titanium, nickel alloys, and tool steel, with full material certifications and traceability.
Primary Alloys
Aluminum AlSi10Mg: The most common aluminum alloy for metal 3D printing. Silicon improves flow and crack resistance; magnesium adds strength. Good strength-to-weight ratio and thermal conductivity. Explore Aluminum 3D Printing
Stainless Steel 316L & 17-4 PH: 316L offers excellent corrosion resistance and elongation for food processing and marine hardware. 17-4 PH reaches 198–199 ksi UTS in the H900 condition for tooling inserts and wear-resistant components. Explore Stainless Steel 3D Printing
Titanium Ti-6Al-4V: Combines high strength, low density, and excellent biocompatibility. Achieves 144–153 ksi UTS with 15–18% elongation. Dominant material for aerospace brackets and medical implants. Explore Titanium 3D Printing
Other Metals: Inconel 718 (nickel superalloy for extreme temperatures), cobalt chrome (Co28Cr6Mo for dental and orthopedic implants), and tool steel 1.2709 (maraging steel for molding inserts and fixtures).
Powder Metallurgy Notes
Material selection in metal additive manufacturing is not identical to CNC machining. Powder metallurgy behaves differently than wrought bar stock. Grain structure, heat treatment response, and surface finish all vary.
For inexpensive aluminum, scrap is irrelevant. For titanium at $80 per kilogram and Inconel at $120 per kilogram, scrap becomes the dominant cost in CNC machining. DMLS uses only the powder deposited, with 85–98% of unfused powder recovered and reused.
Material
Aluminum
Lightweight brackets, heat exchangers, and automotive prototypes with excellent strength-to-weight ratio.
Material
Stainless Steel
316L for corrosion resistance and 17-4 PH for high-strength tooling and wear-resistant applications.
Material
Titanium
Grade 5 titanium for aerospace and medical applications requiring high strength-to-weight ratios.
Material
Nylon
Lightweight brackets, heat exchangers, and automotive prototypes with excellent strength-to-weight ratio.
Post-processing
Post-Processing & Finishing for DMLS Parts
An as-printed DMLS part is rarely the final delivered part. Post-processing commonly adds 30–50% to the as-printed price. We quote fully loaded delivered costs upfront — no surprises.
| Process | Description | Best For |
|---|---|---|
| Heat treatment & stress relief | Relieves residual stresses from rapid heating/cooling cycle | All DMLS metals to prevent warping |
| Hot isostatic pressing (HIP) | High temperature and pressure close microporosity, push density above 99.8% | Aerospace and medical critical parts |
| Support removal | Wire EDM and hand finishing for overhangs and anchors | All parts with overhangs greater than 45° |
| Bead blasting | Uniform matte texture, improves surface to Ra 8–12 μm | Cosmetic and functional parts before coating |
| Polishing | Satin or mirror-like surface finish | Decorative parts, optical components, wear surfaces |
| CNC post-machining | Machine critical bores and faces to ±0.001″ (±0.025 mm) | Mating surfaces, threads, and press fits |
The right finish depends on function, environment, and appearance requirements. During DFM review, our engineers recommend post-processing based on your application so you avoid unnecessary treatments and late-stage issues.
Engineering data
DMLS Specifications & Precision
Understanding the physical limits of the process helps you design parts that print successfully the first time. Here are the specifications engineers need to know.
DMLS Technical Specifications
| Parameter | Standard | Precision / Max |
|---|---|---|
| Layer thickness | 20–60 μm | 20–30 μm (fine) |
| Dimensional accuracy | ±0.1 mm (as-printed) | ±0.025 mm (CNC finish) |
| Density | 95–98% (DMLS) | 99.8% (with HIP) |
| Build volume | 250 × 250 × 300 mm | 500 × 280 × 360 mm |
| Surface roughness (Ra) | 10–20 μm (as-printed) | 0.8–3.2 μm (CNC machined) |
| Min feature size | 0.5 mm walls (practical) | 0.3 mm (aluminum, possible) |
Precision tolerances on critical features are achieved via CNC post-machining, with CMM inspection and dimensional reports available for shipment.
When to Specify CNC Finishing
- As-printed tolerance (±0.1 mm): sufficient for prototypes, non-critical fitment, and internal features where surface finish is not cosmetic.
- CNC finishing (±0.025 mm): required for bearings, guides, locating features, mating bores, press fits, and threaded holes.
- Cost impact: post-processing including CNC machining typically adds 30–50% to the as-printed price, quoted upfront with no surprises.
- Engineering support: upload your CAD files to confirm achievable tolerances and receive DFM guidance on which features need machining stock.
Quality Assurance
Quality Assurance & Inspection
Quality is not a final check. It is built into every stage of our metal 3D printing process, from powder verification to final dimensional inspection.
Our Quality Systems
- ISO 9001 certified quality management system
- AS9100 certified for aerospace quality standards
- Full material traceability from raw powder to finished part
- In-process inspection at multiple production stages
- CMM final inspection on Coordinate Measuring Machine equipment
- Surface roughness testing for finish validation
- First article inspection reports for production approval
- 100% inspection or AQL sampling per customer requirements
What You Receive with Every Shipment
Every order includes a comprehensive inspection report documenting key quality data for your DMLS metal parts.
- Dimensional measurements against your drawing
- Material certification and traceability
- Surface finish verification when specified
- Pass/fail status for all critical dimensions
- Inspector signature and inspection date
Applications
Industries We Serve with Metal 3D Printing
Metal 3D printing is not a universal solution, but in the right applications, it fundamentally changes what is possible across aerospace, medical, automotive, and tooling.
Industry
Aerospace & Defense
Lightweight brackets, ducting, and structural components in Ti-6Al-4V. Topology optimization reduces weight by 30–50% while maintaining load capacity. FAA and EASA approved SLM parts for commercial aircraft.
Industry
Medical Devices
Patient-specific implants, surgical instrument components, and porous lattice surfaces that promote bone ingrowth. Built in biocompatible titanium or cobalt chrome with full inspection reporting.
Industry
Automotive
Functional prototypes, complex intake manifolds, and aluminum heat exchangers with internal fin geometries that maximize thermal performance in minimal package space.
Industry
Tooling & Molds
Conformal cooling channels that follow mold contours, reducing injection cycle times by 30–50%. DMLS builds geometries that conventional drilling cannot produce.
Industry
Electronics
Aluminum enclosures, copper heat sinks, and complex mounting brackets with integrated thermal management features and precise mounting geometries.
Industry
Industrial Equipment
Steel and stainless steel brackets, wear-resistant guides, and custom tooling components for machinery, automation, and industrial systems requiring complex geometries.
Volume strategy
DMLS vs. CNC Machining: Choosing the Right Process
Metal 3D printing and CNC machining are complementary processes with different economic break-even points. The right choice depends on quantity, geometry, material, and tolerance requirements.
Prototype & Low-Volume (1–20 units)
DMLS wins on cost and speed for small quantities. No tooling, no setup fees, no programming.
- No minimum order quantity—order 1 piece
- 3–7 day standard lead times
- Same material properties as production parts
- Free DFM feedback for manufacturability
- Ideal for titanium and Inconel where CNC waste is expensive
Medium-Volume Crossover (20–100 units)
The gray area where geometry and material waste tip the balance. Simple aluminum brackets cross over at 20–30 pieces; complex housings may not cross over until 80–150 units.
- DMLS cost is flat with geometric complexity
- CNC cost scales directly with every pocket and undercut
- Material waste dominates for titanium and Inconel
- Hybrid approach: print near-net, machine critical features
High-Volume & CNC Hybrid (100+ units)
CNC machining becomes cheaper per part above roughly 100 units. At Baetro, you do not need separate shops.
- CNC programming and fixturing amortized across volume
- DMLS for prototypes, CNC for production—same quality system
- Print near-net-shape and finish on our 5-axis centers
- One supplier, one project manager, one accountability
How it works
Our DMLS Metal 3D Printing Process
Working with Baetro is straightforward. Here is the controlled process from CAD file upload to finished metal parts.
Upload Your CAD File
Send your design in STEP, IGES, STL, or native CAD format. STEP and STP are preferred because they preserve design intent for manufacturability reviews.
DFM Review & Orientation
Our engineers orient the part to minimize support structures, balance thermal stress, and optimize surface quality on critical faces. We nest your part to maximize machine utilization.
Receive Quote & Approve
In under 60 seconds, review pricing, lead time, and manufacturability notes. Select material, finish, quantity, and shipping method. Your project manager confirms the schedule.
DMLS / SLM Printing
Parts are printed in an inert argon or nitrogen atmosphere. Build times vary from 8–12 hours for small brackets to 40–60 hours for large aerospace manifolds.
Post-Processing & Heat Treatment
All parts receive stress relief. Supports are removed via wire EDM and hand finishing. Optional HIP, bead blasting, and polishing are applied based on your specification.
Final CNC + Ship
Critical features are machined on our CNC centers to ±0.001 inches. Final CMM inspection, documentation, and worldwide express shipping complete the order.
Cost considerations
Metal 3D Printing Cost Factors
Understanding what drives DMLS costs helps you make informed design and material decisions.
- Material: Aluminum powder is economical; titanium and Inconel favor DMLS due to 85–98% powder recovery vs. 70–80% CNC waste.
- Part Geometry: DMLS cost is flat with complexity. A lattice structure and a solid block take similar machine time if they occupy the same envelope.
- Tolerances: As-printed ±0.1 mm is cheapest. CNC post-machining for ±0.025 mm adds 30–50% but is essential for mating features.
- Post-Processing: Heat treatment, HIP, bead blasting, and polishing are common adders. We quote fully loaded costs upfront.
- Order Quantity: DMLS wins below 20–100 units. CNC wins above 100 units for simple geometries. We tell you which is cheaper.
- Lead Time: Standard 3–7 days included. Expedited delivery available for urgent prototypes.
Product categories
Metal 3D Printing Services by Material
Explore our specialized DMLS and SLM printing services tailored to each metal alloy.
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Aluminum 3D Printing
AlSi10Mg DMLS printing for lightweight brackets, heat exchangers, and automotive prototypes with excellent strength-to-weight ratio.
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Stainless Steel 3D Printing
316L and 17-4 PH DMLS printing for corrosion-resistant, high-strength tooling, medical hardware, and marine applications.
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Titanium 3D Printing
Ti-6Al-4V SLM printing for aerospace structural brackets and biocompatible medical implants with superior fatigue resistance.
FAQ
Frequently Asked Questions
Answers to common questions about DMLS vs. SLM, tolerances, materials, lead times, post-processing, and hybrid manufacturing.
What is the difference between DMLS and SLM?
DMLS uses a laser to sinter — partially melt and fuse — metal powder, achieving 95–98% density. SLM uses a higher-power laser to fully melt the powder, achieving up to 99.9% density. DMLS is gentler on certain alloys and historically the standard for tool steel and cobalt chrome. SLM is preferred for pure metals like titanium and aluminum where maximum density matters. For most engineering applications, both produce functional parts.
How much does metal 3D printing cost?
Small, simple parts typically cost $50–$500. Large or complex parts range from $500 to $10,000 or more. Cost is driven by machine time (the dominant factor), material volume, support structures, and post-processing. Post-processing commonly adds 30–50% to the as-printed price. For an exact quote, upload your CAD file — our engine calculates fully loaded pricing in under 60 seconds.
What tolerances can DMLS achieve?
As-printed tolerances are typically ±0.1 mm. For tighter control, we recommend designing critical features with 0.2–0.5 mm of machining stock and finishing them on our CNC centers, where we hold ±0.001 inches (±0.025 mm).
Can metal 3D printed parts be machined afterward?
Yes, and they often should be. CNC post-machining is the standard way to achieve tight tolerances on threaded holes, bores, and mating surfaces. At Baetro, we integrate this into every project that requires it — not as an afterthought, but as a planned manufacturing step.
What file formats do you accept?
We accept STEP, STP, IGES, STL, and most native CAD formats. STEP and STP are preferred because they preserve design intent and allow our engineers to perform manufacturability reviews more effectively.
How strong are DMLS parts compared to wrought metal?
DMLS and SLM parts achieve mechanical properties comparable to — and sometimes exceeding — cast metals. Tensile strength is generally as good as or better than cast equivalents. Fatigue resistance can be slightly lower due to surface roughness and residual microporosity, but hot isostatic pressing (HIP) and CNC machining of critical surfaces address this for demanding applications.
What is the typical lead time for metal 3D printing?
Standard lead time is 3–7 days from order confirmation to shipment. Complex parts requiring extensive post-processing or HIP may extend to 10–14 days. Rush service is available — contact us for expedited scheduling.
Quote-ready manufacturing
Get Started with Metal 3D Printing Services
Metal 3D printing is no longer an experimental process. It is a production-ready manufacturing method that delivers fully dense parts in titanium, aluminum, stainless steel, and nickel alloys — without tooling, without minimums, and with lead times measured in days rather than weeks.
The key is choosing a partner who understands the full workflow, not just the print cycle. At Baetro, we combine DMLS and SLM with precision CNC machining, free DFM feedback, and transparent pricing to give you parts that work the first time. Whether you need a single titanium prototype or a conformally cooled mold insert, our engineers review your design, recommend the right process, and deliver finished parts to your door.
Parts ship in 3–7 days. No minimum order quantity. ISO 9001 & AS9100 certified.
Not ready to upload a file? Contact our engineers to discuss your project, review material options, or get guidance on DMLS vs. CNC selection.