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Metal 3D Printing Service2025-02-06T01:40:32+00:00

Metal 3D Printing Service

Our Metal 3D Printing Service delivers high-precision, durable metal parts with complex geometries, ideal for rapid prototyping and end-use applications.
  • High-precision metal parts with intricate designs
  • Rapid prototyping with reduced lead times
  • Ideal for functional and end-use applications

  • *Certifications: AS9100D | ISO 9001:2015 | ITAR Registered

metal 3d printing service

DMLS Overview

Direct Metal Laser Sintering (DMLS) is an advanced 3D printing technology that uses a high-powered laser to fuse metal powder layer by layer, creating precise, durable parts directly from digital models. DMLS allows for the production of complex geometries that would be difficult or impossible to achieve using traditional manufacturing methods. This technology is ideal for industries requiring strong, lightweight, and high-performance metal parts, such as aerospace, automotive, and medical devices. It offers quick turnaround times and design flexibility, making it a popular choice for both prototypes and end-use applications.

Applications of Metal 3D Printed Parts

Metal 3D printing technology is ideal for prototyping with production-grade materials, creating complex geometries, and producing functional, end-use parts, while reducing metal components in assemblies.

Automotive Components

automatic car industry
  • Engine components
  • Custom tooling
  • Exhaust systems

Aerospace

aerospace industry
  • Turbine blades
  • Brackets
  • Connectors

Industrial Equipment

industral equipment
  • Custom jigs
  • Fixtures
  • Tooling components

Medical

medical devices
  • Surgical instruments
  • Implants
  • Prosthetics

Design Guide for DMLS

Our DMLS guide provides comprehensive insights into the design methods, benefits, applications, and best practices for utilizing Direct Metal Laser Sintering in precision manufacturing.

KingStar Mold’s Capabilities of Metal 3D Printing

MetricUS
High Resolution20 microns0.00079 in.
Normal Resolution30 microns0.0012 in.
Normal Resolution
(X Line*)		Aluminum: 40 microns
Inconel: 60 microns		Aluminum: 0.00157 in.
Inconel: 0.00236 in.
*Only Inconel 718 and Aluminum are available.

MetricUS
High ResolutionAl: 94mm x 98mm x 98mm
70mm x 88mm x 88mm		Al: 3.7 in. x 3.8 in. x 3.8 in.
2.7 in. x 3.5 in. x 3.5 in.
Normal Resolution330mm x 245mm x 245mm13.0 in. x 9.6 in. x 9.6 in.
Normal Resolution
(X Line*)		500mm x 800mm x 400mm19.7 in. x 15.7 in. x 31.5 in.
*Only Inconel 718 and Aluminum are available.

MetricUS
High Resolution0.153mm
Aluminum: 0.381mm		0.006 in.
Aluminum: 0.015 in.
Normal Resolution0.381mm
(0.762mm for Aluminum)		0.015 in
(0.030 in. for Aluminum)
Normal Resolution
(X Line*)		0.381mm
(0.762mm for Aluminum)		0.015 in.
(0.030 in. for Aluminum)
*Only Inconel 718 and Aluminum are available.

For well-designed parts, tolerances of +0.003 in. (0.076mm) plus 0.1% of the nominal length are typically achievable. However, tolerances may vary depending on the part’s geometry.

Finishing OptionDescription
PolishedSurfaces are sanded to the desired grit level, resulting in a somewhat reflective and bright finish, though some sanding lines or marks may still be visible.
BrushedSurfaces are directionally sanded to the desired grit level.
SatinSurfaces are sanded to the desired grit level, then grit blasted and bead blasted for a smooth finish.
StandardSupport structures are removed, and layer lines remain visible.

Metal 3D Printing Materials Comparison Chart

MaterialsResolutionConditionYield Stress (MPa)Ultimate Tensile Strength (MPa)HardnessElongation (%)Details
Stainless Steel (316L)High20 μmStress Relieved38656590 HRB78More Info
Normal30 μmStress Relieved37958688 HRB75
Stainless Steel (17-4 PH)High20 μmSolution & Aged (H900)1,2271,37242 HRC10More Info
Normal30 μmSolution & Aged (H900)1,2341,36542 HRC13
Cobalt Chrome (Co28Cr6Mo)High20 μmAs Built772125539 HRC17More Info
Normal30 μmAs Built820121338 HRC14
Aluminum (AlSi10Mg) High20 μmStress Relieved18026846 HRB15More Info
Normal30 μmStress Relieved22834559 HRB8
Normal40 μmStress Relieved18629650 HRB10
Titanium (Ti6Al4V)High20 μmStress Relieved951105535 HRC15More Info
Normal30 μmStress Relieved85599333 HRC18
Copper (CuNi2SiCr)High20 μmPrecipitation Hardened43449687 HRB23/
Inconel 718High20 μmStress Relieved67698633 HRC36/
Normal30 μmStress Relieved62799330 HRC39
Normal30 μmSolution & Aged per AMS 56631207143446 HRC18
Normal60 μmStress Relieved57295827 HRC40
Normal60 μmSolution & Aged per AMS 56631200138645 HRC19

*These figures are estimates and may vary based on several factors, including machine settings and process parameters. As such, the information provided is not guaranteed or certified. For critical performance requirements, independent lab testing of the additive materials or final parts is recommended.

KingStar Mold’s Post-Processing Capabilities

Heat Treatments

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

Surface Finishing

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

Powder Analysis & Material

  • Traceability
  • Chemistry
  • Particle size and distribution analysis

Mechanical Testing

  • Tensile
  • Rockwell Hardness

Why Use 3D Printing for Metal Parts?

Design Freedom

Metal 3D printing allows for the creation of complex, intricate geometries that would be difficult or impossible to achieve with traditional manufacturing methods. It enables the design of parts with internal structures, lightweight forms, and customized shapes. This freedom reduces material waste and improves part performance.

Rapid Prototyping

With metal 3D printing, prototypes can be quickly produced, tested, and iterated, shortening product development timelines. It eliminates the need for expensive molds and tooling, saving both time and costs. This fast turnaround allows for more efficient design validation and optimization.

Reduced Material Waste

Unlike traditional subtractive manufacturing, which cuts away material, metal 3D printing uses only the material needed for the part, minimizing waste. This results in a more sustainable production process, especially for high-value metals. Reducing waste also helps lower material costs.

Strong and Lightweight Parts

Metal 3D printing produces parts with excellent mechanical properties, including strength, durability, and heat resistance. The technology enables the creation of lightweight structures without compromising strength, which is particularly beneficial for aerospace and automotive industries. These high-performance parts meet the demanding requirements of end-use applications.
components of metal 3d printer

How Does Metal 3D Printing Work?

The Direct Metal Laser Sintering (DMLS) 3D printing process begins with the laser unit (1) generating a high-powered laser beam (2), which is directed by the mirror/galvo motor system (3) and beam steering (3) to precisely melt and fuse metallic powder on the build platform (5). Initially, the laser sinters support structures to the base plate, followed by the part itself. As each cross-section layer of powder is micro-welded, the build platform (5) shifts down, and the recoater blade (7) moves across to deposit the next layer of powder from the powder supply container (8). Layer by layer, this process is repeated until the part is complete. Once the build is finished, parts undergo manual brushing to remove loose powder, followed by heat treatments to relieve stress. Afterward, parts are removed from the platform, and support structures are detached. Final finishing steps such as bead blasting and deburring are done, ensuring the part is nearly 100% dense. Throughout the process, pistons (9) and the powder collection container (10) manage powder distribution and collection, ensuring smooth operation and efficient material handling.

Large Format Metal 3D Printing

Our large format 3D printers can produce metal parts up to 31.5 in. x 15.7 in. x 19.7 in. in materials like Aluminum and Inconel. These large-scale parts are commonly utilized in industries such as aerospace, automotive, energy, and various industrial applications.

FAQs question mark
What industries use Metal 3D Printing?2025-02-03T05:34:43+00:00

Metal 3D printing is used across a variety of industries, including aerospace, automotive, medical, and energy sectors. It is especially useful for creating parts that are lightweight, strong, and able to withstand high temperatures. The technology is also ideal for producing small-batch, customized parts.

How accurate are parts made with Metal 3D Printing?2025-02-03T05:33:36+00:00

Parts made with Metal 3D printing typically have a high degree of accuracy, with tolerances as tight as 0.003 in. (0.076mm) plus 0.1% of the nominal length. However, the final accuracy can vary depending on the complexity of the design and material used. KingStar Mold ensures the highest precision during the printing and post-processing stages to meet customer specifications.

What materials are available for Metal 3D printing?2025-02-03T05:31:58+00:00

We offer a variety of materials for Metal 3D printing, including Aluminum, Inconel, and other high-strength alloys. These materials are chosen for their durability, heat resistance, and suitability for complex manufacturing needs. Material selection is based on the specific requirements of your project.

What is Metal 3D Printing?2025-02-03T05:31:16+00:00

Metal 3D printing is a process that uses additive manufacturing technology to create metal parts layer by layer. The process allows for complex geometries and high-performance components to be made directly from digital designs. It is commonly used for rapid prototyping, end-use parts, and producing complex metal structures.

How can KingStar Mold help with my Metal 3D Printing needs?2025-02-03T05:39:24+00:00

KingStar Mold specializes in precision manufacturing, providing high-quality metal 3D printing services for various industries. With expertise in material selection, part design, and post-processing, KingStar Mold ensures that your project meets the required specifications and is delivered on time.

What is the maximum size of parts that can be printed with Metal 3D printing?2025-02-03T05:38:41+00:00

Our large-format metal 3D printers can handle parts up to 31.5 in. x 15.7 in. x 19.7 in. in size. This capability allows for the production of large, complex metal parts used in various industrial and aerospace applications.

What post-processing is required for Metal 3D printed parts?2025-02-03T05:38:14+00:00

After printing, parts typically undergo various post-processing steps such as support structure removal, heat treatment, surface finishing (e.g., bead blasting or polishing), and inspection. This ensures that parts meet the required mechanical and aesthetic specifications. KingStar Mold also offers custom finishing options to improve part quality.

How long does the Metal 3D Printing process take?2025-02-03T05:37:42+00:00

The duration of the Metal 3D printing process depends on the size, complexity, and material of the part. Smaller parts may take a few hours to print, while larger or more complex designs could take several days. The process is efficient and often faster than traditional manufacturing for intricate designs.

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KingStar Mold specializes in building custom injection molds and manufacturing plastic, silicon & high precision metal parts. With decades of expertise in injection molding, mould/tooling building, CNC machining, 3D printing, and sheet metal fabrication, we provide high-quality solutions tailored to your needs.

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