No Tooling or Fixturing
DMLS builds parts straight from your CAD file, so there are no dies or fixtures to wait on. That cuts lead time and cost, and lets us print several design revisions in a single build.
Direct Metal Laser SinteringServices and Capabilities
Direct Metal Laser Sintering (DMLS) fuses metal powder one layer at a time with a focused laser, building dense, functional parts straight from your CAD file. No hard tooling means fast revisions and tight tolerances on complex geometry.
About Our DMLS Services
In 2004, members of the Evology team brought in an EOS EOSINT M270, one of the first DMLS systems in the United States. We have run the process ever since, building functional metal parts to tight tolerances.
DMLS uses no hard tooling, so we can adjust a design and reprint it without waiting on new dies or fixtures. That keeps revisions fast and short runs affordable.
DMLS is one of several metal additive processes. See how it fits alongside the rest on our manufacturing capabilities page.
Why Choose DMLS?
DMLS earns its place where geometry, weight, and lead time matter more than raw volume. Three traits set it apart from machined and cast metal parts.
Design Flexibility
Because the part grows layer by layer, you can build internal channels, lattices, and consolidated assemblies that are hard or impossible to machine. A design change means a file change, not new tooling.
Range of Alloys
We print aluminum, maraging and stainless steels, Inconel, and titanium, so you can match the alloy to the load, temperature, and corrosion demands of the part.
Applications of DMLS
DMLS suits functional metal parts where the design carries complex internal features or has to hold up under heat, pressure, or load. Here is where it earns its place most often.
Heat Exchangers
Dense metal parts with internal channels that move heat efficiently inside a compact envelope.
Conformal Cooling Inserts
Mold inserts with cooling channels that follow the part, cutting cycle time and reducing warp.
Drill Bits
Custom cutting tools and bits in tool steel for specialized drilling and machining work.
Casting Replacements
Functional metal parts that stand in for castings without the tooling cost or long lead time.
Functional Metal Parts
Load-bearing components in aluminum, steel, Inconel, or titanium for demanding service.
Technical Specifications
DMLS is a powder-bed process that fuses metal one layer at a time with a focused laser, closer to micro welding than to casting or machining. The result is a dense, structurally sound part that holds tight tolerances.
+/- 0.005"Tolerances as tight as five thousandths of an inch (0.13 mm)
Powder bedLayer-by-layer laser micro welding for full-density metal
Since 2004Running production DMLS systems in-house
Free Technical Resources
Below are the different materials we offer for DMLS.
Standard Offering
Click a material for full specs and a downloadable datasheet.
Special Request
Click a material to open its EOS datasheet (PDF).
Our Experience & Capacity
We have run DMLS since 2004 and have grown the fleet as demand has grown, which lets us take on larger builds and react quickly to tight schedules. Our parts ship into automotive, aviation, defense, and medical programs.
Whether you need a single functional prototype or a recurring production part, we can scope the build and recommend the right alloy. Explore the rest of our manufacturing capabilities to see how DMLS pairs with our other additive and traditional processes.
Parts We've Made with DMLS
A sample of functional metal parts we have printed on our DMLS systems, from manifolds and valve bodies to impellers and brackets.
Let's Start Your Next Project
Send us your design and one of our estimators will review it for DMLS. We will confirm the alloy, tolerances, and timeline, then get you a quote.
Related Case Studies
Motorsport · DMLS
DMLS Motor Cooling Sleeve: How Illini Electric Motorsports Engineered Around Thermal Runaway
Illini Electric Motorsports designed an indirect DMLS aluminum cooling sleeve with a helical coolant path to keep their AMK motors below the derating cliff. The printed geometry cut convective thermal resistance in half and eliminated derating in endurance running.
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Motorsport · DMLS
DMLS Formula SAE Oil Pan: How UW-Platteville Reduced Weight by 37%
Pioneer Racing designed the PR26 structural dry-sump oil pan for DMLS from the start, cutting weight 37% versus PR25 and 57% versus the original machined concept, while holding a factor of safety above five. The lighter pan helped the team to its best Formula SAE Michigan finish in program history.
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Motorsport · DMLS
From CAD to Metal: FDF Raceshop’s Generatively Designed Handbrake & Clutch Pedal
Josiah Fallaise of FDF Raceshop designs his own performance parts with generative design, then needed a manufacturer who could print them in metal without cutting corners. Evology printed his hydraulic handbrake and BMW E46 clutch pedal in AlSi10Mg on an EOS M 290, North American made, structurally sound, and detailed enough to show every decision the software made.
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Motorsport · DMLS
Advancing Structural Innovation: Pioneer Racing FSAE's PR25 DMLS Oil Pan
For their 2024-2025 season, Pioneer Racing reimagined the PR25 powertrain as part of the chassis. The result was a DMLS oil pan that ties the engine to the rear plates, enables a dry sump system, and could not be machined conventionally.
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Motorsport · DMLS
Reinventing Performance: Evology & MSOE Baja's Lightweight Rear Knuckles
MSOE's Raider Racing Baja team redesigned their rear suspension knuckle with DMLS. The new part cut weight, improved structural integrity, and sharpened suspension performance, all on a tight pre-race timeline.
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