DMLS Materials - Technical Specifications

The UK’s leading provider of high 

quality, functional prototypes, aesthetic 

models and low volume production 

components in plastic using Selective 

Laser Sintering (SLS) and in metal 

using Direct Metal Laser Sintering 

(DMLS) technologies 

www.3trpd.co.uk

I N T R O D U C T I O N 

3T 

RPD Ltd is a market leader in 

Rapid Product Development 

providing Rapid Prototyping and 

Rapid Manufacturing services to a 

diverse range of industry sectors ... 

... including Aerospace, Architecture, 

Automotive, Dental, Medical, FMCG, Marine, 

Defence and Pharmaceutical. With the UK’s 

largest Selective Laser Sintering (SLS) facility, 

we are now leading the way in the supply of 

metal parts using Direct Metal Laser Sintering 

(DMLS) throughout the UK and Europe. 

We specialise in the cost-effective, fast 

and extremely accurate production of 

complex and functional prototypes, 

aesthetic models and low volume 

production components directly 

from 3D CAD data, negating the need 

for conventional tooling. 

Offering 

a wide range of both plastic and 

metal materials, together with some 

SLS combining 

functionality with 

quality aesthetics 

of the world’s largest Laser Sintering machines, we 

can supply parts in just a matter of days. And with 

Engineers, Architects and Designers using these 

technologies to revolutionise the speed at which 

products can be brought to market coupled with 

new opportunities for low volume production, 

Rapid Manufacturing is becoming a reality for many. 

With innovation and research at the forefront 

of our business, we have the right skills in place 

through our team of highly trained engineers and 

finishers to ensure that we consistently gain the 

best from these technologies. We are committed to 

quality assurance in our manufacturing processes, 

products and delivery and in recognition of this, 

we have gained both ISO 9001:2000 and ISO 

13485:2003 Medical Devices accreditations. 

Example of Rapid 

Manufacturing; bed of Aerospace 

parts in Cobalt Chrome 

Example of how DMLS 

can be used in a 

medical application 

As we continue to expand into other market sectors 

and develop our service offering, the ISO quality 

framework will ensure that we offer exceptional 

reliability and service, and the highest quality products 

that our customers have come to expect from us. 

Dental Copings and Bridges 

Functional SLS prototype 

tested in true working 

environments 

By asking for the impossible, obtain the best possible 

Italian Proverb

W H A T I S S L S & F I N I S H I N G 

What is Selective Laser Sintering? 

SLS is a process of fusing together layers of 

powder (eg. Nylon, Glass Filled Nylon or Alumide) into 

a 3D model by a computer-directed heat laser. 3D 

CAD data of a new product or prototype component is 

sliced into layers, and the lasers sinter (melt) the powder 

layer by layer. Additional powder is deposited on top of 

each solidified layer and again sintered. 

The process is self-supporting and parts can 

therefore be nested together. The ‘selective’ nature 

of the lasers enable complex geometries to be 

achieved without compromising on functionality. 

SLS provides the highest level of functionality 

combined with speed that is currently available. 

We are uniquely able to build 

prototypes on both EOS 

and 3D Systems machines, 

boasting some of the world’s 

largest SLS machines - four 

EOS P700/730s, two EOS P380’s and a 3D Systems HiQ 

2500 Plus - thus enabling us to provide the optimal 

machine to meet our customers’ requirements. Large 

parts are built in single pieces up to a build volume 

of 700x380x580mm on the P700/730’s; the reduced 

need for joints and post-assembly dramatically 

increasing their functionality. 

www.3trpd.co.uk 

The P380’s allow 

parts to be built up to 620x340x340mm, and smaller 

parts with finer detail can be produced on the DTM. 

What are the finishing options? 

The layer based construction techniques 

of SLS offer significant benefits in terms of build 

speed, however it can sometimes give a 

stepped surface finish. 

From a purely functional 

aspect this is seldom a problem, however 

from the aesthetic perspective they may require 

additional finishing. 

Our skilled team of 

finishers combine the 

functionality of SLS 

parts with high quality 

aesthetics, with minimal time added to the delivery. 

Providing a range of finishing techniques from simply 

adding a colour or highlighting certain areas, to fully 

finished marketing models, a finished prototype can 

play a vital role in functionality testing, securing tender 

bids, design verification and marketing photography. 

Furthermore, we have pioneered a low cost method 

of improving the visual impact of our prototype 

components with a revolutionary colouring 

process. 

Single parts or large batches can be 

supplied in a range of standard colours. Requiring 

no surface dressing, this post-process is usually 

covered by a flat charge irrespective of parts count. 

Assemblies become 

clearer and resilience to 

handling discolouration is enhanced, giving a far 

better communication of design intent.

F U N C T I O N A L I T Y 

How functional are SLS prototypes? 

A simple test was carried out by 

parking an Audi A4 car on one of our SLS 

prototypes! The housing, 40mm high with a 6mm 

wall section, was to be cast in Steel in production. The 

result was no damage to the part (apart from some 

tyre discolouration!). 

In order to demonstrate functionality 

still further, we purchased a Smart Car 

with the intention of replicating or redesigning 

components, re-building them in SLS and 

testing them in everyday conditions. Together with 

Crucible Industrial Design Ltd, the complete front 

end of the Smart car was re-designed and built in SLS, 

fitted to the car and driven in every road and weather 

condition imaginable for over 2,000 miles, with no 

detrimental effect to the SLS components. 

The project began conventionally, 

with designers from Crucible 

submitting rendered sketches of a 

re-designed front end. Due to the 

reverse engineering aspect of the project, 3D Scanners 

digitised the front of the car to provide a digital surface 

that could be read into SolidWorks. Once a final design 

was decided upon, Crucible created a 3D CAD model 

which was then supplied to us for SLS components to 

be built. 

The ability of the Smart car’s body panels to be 

completely removed and replaced within four hours 

allowed access to the chassis fixtures and fittings, 

which gave fixed anchor points for the final design. 

Critical components such as the door pillars and 

bumper fixtures had to be considered, and the 

windscreen washer and brake fluid reservoirs had to 

remain accessible to ensure the car’s performance 

wasn’t compromised. 

The car was driven at speeds of up to 70mph, in wet, 

muddy conditions as well as hot, dry weather, and 

parked outside in sub-zero temperatures. It was taken 

on some journeys of almost 3 hours without stopping. 

The success of this project has proved, beyond 

doubt, the capability, functionality and durability 

of our SLS prototypes. 

A closed mind is like a closed book; just a block of wood 

Chinese Proverb

C A S E S T U D Y 

Record RSS is a market leader 

in the provision of innovative and 

reliable play solutions providing safe play 

equipment for children of all ages who now 

demand more fun, increased challenges 

and stimulating equipment to mirror their 

influences and aspirations. 

Their designers were challenged to come up with 

a dynamic, exhilarating ride for children aged 7 

through to adulthood and from initial ideas came 

the RidgeRider; an elliptical track with a moving 

seat, likened to a mini roller coaster. The inner 

workings of the seat and how it could be safely 

mounted onto the track took months to finalise, 

but then they needed a method of creating a costeffective, 

working prototype of it for testing on the 

track itself. 

They turned to us as our Selective Laser Sintering 

(SLS) technology was the ideal solution and the 

best way of building the seat in a material that was 

durable enough to withstand functional testing, 

within a short leadtime. Special features were 

incorporated into the complex internal workings 

of the seat to ensure the safety of fingers and hands 

of both riders and spectators. 


Made in two mirrored parts, it simply clipped 

together, thereby creating a protective housing over 

the track as well as a functional seat for the rider. 

The Nylon material used to produce the prototype 

model emulated the final production material; rotomoulded 

polyethylene; so much so in fact, that 

our Technical Sales Engineer actually rode it when 

it was being demonstrated at an exhibition! This 

functionality enabled the designers to prove their 

design prior to going into 

final production, without 

the need for expensive 

tooling. 

The RidgeRider being 

demonstrated at Saltex 2007 

“Andrew Kadis, Design Manager at Record RSS said, 

“The quick turn around from sending 3T our CAD data to 

receiving the SLS prototypes enabled us to demonstrate the 

product to the British Standards Institution for testing, as 

well as allowing us to show the product at our major annual 

exhibition, Saltex 2007, where it made a huge impact.”


Architect Zaha Hadid 

consistently pushes the 

boundaries of architecture and urban 

design. We produced scale models of 

the Guggenheim Museum in Taichung, 

Taiwan, which were delivered as an 

architectural presentation to the office 

of the Mayor of Taichung, to promote 

the project. 

Due to the complex organic forms of Zaha’s design 

and the need to show an accurately presented 

final design, SLS was deemed the best solution for 

achieving and meeting their requirements. 

To place the model in context, the laser sintered 

‘building’ was merged with a CNC ‘landscape’ to 

underline the synergy of the proposal. 

Over 2m long, the resulting 3D model gave an 

incredible visual image of the proposed building 

when compared alongside the computer generated 

artist’s impression, allowing the Mayor’s office to see, 

touch and feel an actual tactile scale version of the 

proposal. 

“Dillon Lin, Project Architect for 

Zaha Hadid says “The SLS piece gave 

a very convincing presentation model 

that the mayor of Taichung is putting 

to good use in promoting the project. 

When accuracy is required with complex forms, SLS proves 

to be an economic process for producing models of these 

forms when compared to other, more expensive options, 

including making them by hand, which is extremely labour 

intensive.” 

” 

By learning you will teach; by teaching 

you will learn 

Latin Proverb


Urban Bicycle is a polymer bicycle 

designed to meet the needs of the 

inner-city commuter and town cyclist. 

We produced functional and aesthetically pleasing 

prototypes to assist Paul Wolfson in his final year 

of study in Industrial Design and Technology at 

Loughborough University. 

Paul’s intention was 

to challenge traditional bicycle manufacturing 

techniques and prove that polymeric materials would 

be suitable to produce a viable product. 

The simplistic design was effectively replicated using 

the SLS prototyping technology, with the parts being 

produced directly from CAD data used extensively 

during the design process for both development and 

presentation of the concept, saving a considerable 

amount of time in creating a final prototype. 

The SLS prototype had the necessary physical 

properties to fully test the concept, and was suitable 

to undergo further modelmaking work in order to 

make it appear as the desired design would. 

“Paul Wolfson, Designer of the 

Urban Bike says “The functionality of 3T’s SLS 

prototypes far exceeded my expectations, as I 

never envisaged that I would actually be able to 

assemble the bicycle and ride it! Prototyped at the 

intended wall thickness of the production part 

gave me a realistic representation of my design, 

without any modifications having to be made.” 


”

Stewart Golf design, 

develop and manufacture 

luxury powered golf caddies and 

recently launched the F1 Lithium to the 

market; a fully remote-controlled top of 

the range golf trolley, retailing at £2,500. 

SLS model before and after finishing 


It was imperative that the new design was tried and 

tested before going ahead with full production and, 

using our Rapid Prototyping services, they were able 

to generate 3-dimensional models direct from 3D CAD 

data using Selective Laser Sintering (SLS) technology. 

The resulting tactile models enabled the designers 

to make small design modifications along the way, 

without the need to invest in unnecessary tooling 

which could prove expensive and time-consuming. 

During previous product development, the designers 

at Stewart Golf have used both Stereolithography (SLA) 

as well as SLS. However, they found that whilst SLA 

can be produced to a high quality finish, the material 

Furthermore, the self-supporting nature of the SLS 

process enables large hollow parts to be produced. 

With some clever positioning of through-holes by the 

designers, our modelmakers were able to remove the 

unsintered powder from inside the cavity walls. The 

holes were then carefully sealed to allow a smooth 

finish to be achieved. The SLS Nylon material emulated 

that of the actual production material, thereby allowing 

the designers to create a realistic weight for the parts, 

making their testing all the more accurate. Had the 

parts been produced in several pieces and later joined 

together, this could have compromised both the 

strength and functionality. 

itself was too weak for functional testing and became “Jon Miller, Engineering Director at Stewart Golf says “As 

good as 3D CAD systems are, there is nothing better than having a realistic 

affected by atmospheric conditions, making them and fully functional product in your hands. The SLS models enabled the 

either brittle or too flexible. However, it is possible to Stewart Golf team to discuss every feature of the product in great detail, 

ranging from the overall appearance and styling of the product to the 

achieve an extremely high standard of finishing with smallest of tooling details. The complete SLS prototype was also used for 

SLS. Ours team of skilled modelmakers and finishers demonstration purposes at our distributors, enabling them to appreciate 

the concept and performance improvements. Furthermore, the individual 

can create high quality aesthetics, generating a model components along with 3D CAD data were taken to our suppliers to ensure 

that is comparable to the final manufactured item. the parts could be easily manufactured without the need for expensive 

tooling modifications.” 

” 

The resulting prototype model of the F1 Lithium Golf 

Trolley not only enabled Stewart Golf to produce 

photography for pre-product launch literature, but 

A bargain is something you don’t need 

at a price you can’t resist 

the models were also robust enough to allow final 

English Proverb 

product testing both on and off the golf course.


Nottingham 

University 

Hospital Trust, Loughborough 

University and Delcam Ltd have collaborated 

on the ‘Facemaker’ project, taking advantage 

of our 3-dimensional modelling techniques 

to offer alternative methods to patients who 

require a facial prosthesis. 

By removing the need for direct contact in making the 

prosthetics and rehabilitation aids, digital methods 

offer substantial benefits to patients following cancer, 

facial trauma or a congenital abnormality of the face. 

Traditionally, a direct mould of the face would have 

been taken which is heavy, easily distorted, time 

consuming and potentially extremely painful to 

the patient. 

Maxillofacial Prosthetists would then 

generate a replica of the patients’ missing skin and 

bone using craft based skills; sculpting, constructing 

and moulding the prosthesis to match as close as 

possible the missing part. These techniques have not 

changed significantly for 30 years. 

The ‘Facemaker’ project makes use of the ‘Cobra Fast 

Scan’ from Polhemus, USA, collecting data directly 

from the patient in a non-contact manner. 


This 

enables the Maxillofacial Prosthetists to reproduce 

the missing part using Delcam’s CopyCAD software 

(Figure 1). They then mirror image the remaining parts 

to generate a prosthesis template for the defect site, 

which is then manufactured using our Selective Laser 

Sintering (SLS) technology (Figure 2). The mirrored 

part creates a template for the final sculpting of a new 

prosthesis which is then adapted to accurately fit the 

patient (Figure 3). 

Fig. 1 

Fig. 3 

Furthermore, this innovative project can help patients 

who have suffered facial burns and require pressure 

therapy splints or head radiotherapy immobilisation 

splints, and also assist in surgical planning for cleft 

lip and palate babies, where it is extremely difficult 

to obtain 3D images of the affected areas unless 

the baby is put to sleep. 

As more challenging and 

complex procedures are being carried out, the ability 

to inexpensively and efficiently produce customised 

devices and models using Rapid Prototyping 

techniques is becoming increasingly 

attractive for many specialist areas 

within the medical sector. 

Fig. 2 

Figure 1 

Ear scan data manipulated in CopyCAD 

Figure 2 

Mirror image of the remaining right ear 

rapid manufactured (3T) to produce a 

prosthesis template for the defect side 

Figure 3 

Final ear prosthesis in position


Marks Barfield Architects 

believe that good design 

transforms the quality of the 

environment and aim to provide an 

architecture that is innovative, 

sustainable, an imaginative response to 

context and a pleasure to experience. 

One such example of this is the Xstrata Treetop 

Walkway in Kew Gardens, due to open in Spring 

2008 as part of the ‘Year of the Tree’ celebrations. 

This will be a thrilling experience, taking visitors 18m 

high into the tree canopies along a 200m long loop 

for a birds-eye view of Kew. It will provide insights 

into the special role of trees in our breathing planet 

and intimate views of deciduous woodland and its 

inhabitants from within the tranquility of the leaves. 

Marks Barfield used their in-house 3D CAD software 

to design the treetop attraction and commissioned 

us to build scale models of some of the key elements 

of the structure to illustrate the concept, namely the 

main stair tower and a section of the walkway. 

As the UK’s leading specialist in Rapid Prototyping, we 

used our Selective Laser Sintering (SLS) technology 

to translate the CAD data into tactile, 3-dimensional 

models. SLS lends itself perfectly to creating complex 

shapes and surfaces, and is a much quicker, more 

accurate and cost-effective process when compared 

to other more traditional model-making techniques. 

Produced in Nylon, the models gave an extremely 

accurate representation of Marks Barfield’s design, 

with the complex arrangement of the walkway truss 

bracing elements being precisely replicated. 

Our team of skilled finishers and modelmakers used 

a fine mesh material to replicate the sides and floor 

of the walkways, painstakingly attaching it by hand, 

before sending the models to Andrew Ingham & 

Associates, who added trees and people to give a true 

representation of the design. 

SLS Model of 

main Stair Tower 

A picture paints a thousand words 

American Proverb


Finished model giving a true representation of the design 

Photographs of the actual structure in Kew Gardens, opened Spring 2008 

“Chris Smiles says “Workflow between us and 3T was extremely efficient, with no 

information being lost in translation between our design data and the generation of 

the models. For a structure this complex, having an actual 3D model enabled us to 

evaluate the proposal more effectively than simply relying upon a 2- or 3-dimensional 

virtual image. The model itself has been a valuable tool for Kew in promoting the 

project to potential sponsors and stakeholders” 

www.3trpd.co.uk/architecture


PSM Instrumentation 

is a UK designer 

and manufacturer of specialised process 

measurement/control instrumentation for the Marine, 

Chemical, Water and Food & Beverage industries. 

Their unique Water Level Alarm/Indicator provides a 

simple, robust and reliable solution where an immediate 

visual warning is needed of the possible hazards of 

flooding, eg. in underground high voltage sub-stations. 

Their requirement was for 8,000 units, and whilst 

we are specialists in the fast, accurate production 

of one-off prototype components, we also offer the 

economical manufacture of small series parts as 

final products; namely Rapid Manufacturing; a 

fast, flexible and cost-effective method of generating 

otherwise ‘impossible to build’ end-use parts directly 

from CAD data, with no tooling required. 

PSM’s design consisted of a multi-component unit of 

The design required a lightweight production 

material to aid the buoyancy of the product. The 

Nylon used in the SLS process proved ideal, and the 

ease with which the parts could be assembled enabled 

the unit to be sealed and made waterproof without 

any additional post-processing work. 

60mm 

When the float rises with incoming floodwater, the 

internal spring mechanism ‘latches’ at the highest 

recorded level. The flexibility and ‘spring-like’ action 

of the SLS material enables the latching function to 

work extremely efficiently. 

four parts and the physical attributes required by the 

“Sean Lane, Technical Support at 

main housing took full advantage of the SLS process, PSM Instrumentation Ltd says “SLS 

as it enables part design to be unconstrained and 

was the preferred method of manufacture 

as due to the shape of the components it 

functionality-led. The float housing could be built in would have been too expensive to have 

one piece as the ‘selective’ nature of the SLS process them machined from anything solid 

or cast, and the leadtimes would have 

enables complex geometries to be achieved, such been much longer than offered by 3T’s 

” 

as holes and cavities, with the ‘unsintered’ or loose technology.” 

material simply being removed and recycled for future 

use. The internal workings incorporated undercuts, 

levers and living springs essential to its mechanical 

function. 

Furthermore, the float 

needed to be of high visibility, so our revolutionary 

colouring process was used to colour the parts a 

bright orange and yellow. 

< Float 

assembly 

with reset 

levers (cut) 

Assembled 

float > 

Advice is least heeded when most needed 

English Proverb


Ian 

Helmore, a water treatment 

specialist, used our SLS services to 

produce prototype components for his latest 

invention; Steri-Spray®, which appeared on 

Dragon’s Den; BBC TWO’s business venture 

capitalist programme. 

During routine water testing at a hospital Ian detected 

a positive Legionella sample on one of the showers. 

The hospital had to take all 50 of their showers 

out of service for two weeks and Ian felt this was 

unacceptable. As a result he invented the Steri-Spray® 

range of showers. 

During its development, Ian needed to prototype 

his design in order to assemble and test it, as well 

as presenting an aesthetic model of it to potential 

investors. He therefore used our Rapid Prototyping 

expertise to obtain prototypes using Selective Laser 

Sintering (SLS) technology. Over 20 individual 

components that make up the shower system 

were produced in Nylon, including inserts, tubes, 

back plates, covers, connectors and the shower rose 

itself. Our specialist team then expertly finished and 

painted the parts, making them look like the final 

manufactured product. 

Ian was able to demonstrate the concept to the 

Dragons; a panel of 5 successful multi-millionaire 

business people. His pitch was for a £145,000 

investment for a 10% stake in his potentially lifesaving 

invention. Theo Paphitis was willing to split 

the deal with Deborah Meaden, and Ian secured the 


full £145,000 investment for 40% 

of his business shared between the 

two Dragons. 

This investment meant that Steri- 

Spray® could move toward production 

within a very short period of time. 

More importantly, Deborah and 

Theo’s invaluable business experience 

will assist Ian in making Steri-Spray® 

become a worldwide commercial 

brand name. 

“Ian Helmore says “The laser sintering process at 3T was new to 

me and just what was required to prove that our expensive tooling 

for Steri-Spray was going to be correct prior to ordering it. I was 

given a first rate, personal service from the moment I sent the files, 

to when I received the final finished products. The finishing process 

was absolutely superb and done with such attention to detail 

” 

that people think they are the actual manufactured products.”

Largest SLS Bureau in the UK - 3T’s SLS Machines 

EOS P730 EOS P380 3D Systems HiQ 

Quantity: 4 off 2 off 1 off 

Laser Type: CO 2 (twin) CO 2 CO 2 

Laser Spot Diameter: 0.75mm 0.75mm 0.45mm 

S L S P L A N T L I S T 

Layer Thickness: 

Build Chamber/ 

Part Size: 

Materials: 

Our SLS facility 

0.15mm 

700 x 380 x 580mm 

(single piece) 

• Nylon (Polyamide 

PA2200) 

• Glass Filled Nylon 

(Polyamide PA3200) 

0.15 to 0.2 mm 

depending on material 

340 x 340 x 620mm 


• Alumide 


PA2200) 



• PrimeCast 101 

(Polystyrene) 

0.1mm upwards 

depending on material 

330 x 280 x 457mm 



PA2200) 



Keep quiet and people will think you a philosopher 

Latin Proverb

S L S M A T E R I A L S 

Nylon 12 (Polyamide PA2200) 

By far the most common material used in SLS, parts have good long term stability, offering resistance to most 

chemicals. It is harmless to the environment and safe to use with foodstuff. Complexity is irrelevant and 

the material delivers the impact strength and durability required for functional testing. Tensile and flexural 

strength combine to make tough prototypes, with the flex associated with many production thermoplastics. 

It is able to emulate living hinge designs, certainly to 20+ cycles. The material is non-hygroscopic, thereby 

negating the requirement to seal the surface on components being used with liquids. 

Glass Filled Nylon 12 (Polyamide PA3200) 

This is the Glass Filled variant of PA2200. Providing greater rigidity, the glass-filled blend is perfect when 

prototyping rigid parts intended for production in advanced engineered thermoplastics, and is the right 

choice for functional testing. Form, fit and functional testing can now be completed without sacrifice. 

The filler is glass bead and not fibre, hence the part predominantly increases in stiffness but not strength. 

Filler ratios approximately 40%. The material is non-hygroscopic, thereby negating the requirement to 

seal the surface on components being used with liquids. 

Polystyrene (PrimeCast 101) 

This is a Polystyrene material originally conceived as a sacrificial master for investment casting purposes. In 

lieu of making a tool the CAD design would be manufactured directly in this material and the component 

then treated sacrificially as per wax in investment casting. For complex or short lead-time items, this 

can offer significant speed and cost savings. Subsequent work has highlighted how well this material 

functions as a master pattern for Vacuum Casting as an alternative to Stereolithography. 

Alumide 

The manufacture of stiff parts of metallic appearance for applications in automotive (eg. wind tunnel 

tests or parts that are not safety-relevant), tool inserts for injecting and moulding small production runs, 

illustrative models (metallic appearance), education and jig manufacture, among other aspects. Surfaces 

of parts can be finished by grinding, polishing or coating. An additional advantage is that low tool-wear 

machining is possible eg. milling, drilling or turning. 


Selective Laser Sintering Materials

ALUMIDE NYLON GLASS FILLED NYLON POLYSTYRENE 

S L S M A T E R I A L S 

MATERIAL PROPERTIES VALUE UNITS VALUE UNITS VALUE UNITS VALUE UNITS 

Density of lasersintered 

part 

1.36 ± 

0.05 

g/cm³ 0.9 - 0.95 g/cm³ 

1.23 

- 1.28 

g/cm³ 

0.70 

- 0.85 

g/cm³ 

MECHANICAL PROPERTIES VALUE UNITS VALUE UNITS VALUE UNITS VALUE UNITS 

Tensile modulus 

Tensile Strength, 

X-/Y-direction 

Tensile Strength, 

Z-direction 

3800 ± 

150 

N/mm² 

1700 ± 

150 

46 ± 3 N/mm² 45 ± 3 

N/mm² or 

MPa 

N/mm² or 

MPa 

3200 ± 

200 

48 ± 3 

N/mm² or 

MPa 

N/mm² or 

MPa 

1600 ± 

250 

N/mm² 

5.5 ± 1.0 N/mm² 

1.2 ± 0.3 N/mm² 

Elongation at break 3.5 ± 1 % 20 ± 5 % 6 ± 3 % 0.4 ± 0.1 % 

Flexural modulus 

Charpy – Impact 

strength 

Charpy – Notched 

impact strength 

Izod – Impact 

strength 

Izod – Notched 

impact strength 

Ball Indentation 

Hardness 

3000 ± 

150 

N/mm² 

1240 ± 

130 

N/mm² or 

MPa 

2100 ± 

150 

N/mm² or 

MPa 

29 ± 2 kJ/m² 53 ± 3.8 kJ/m² 35 ± 6 kJ/m² 

4.6 ± 0.3 kJ/m² 4.8 ± 0.3 kJ/m² 5.4 ± 0.6 kJ/m² 

32.8 ± 3.4 kJ/m² 21.3 ± 1.7 kJ/m² 

4.4 ± 0.4 kJ/m² 4.2 ± 0.3 kJ/m² 

77.6 ± 2 98 

Shore D hardness 76 ± 2 80 ± 2 

THERMAL PROPERTIES VALUE UNITS VALUE UNITS VALUE UNITS VALUE UNITS 

Melting Point 172 - 180 °C 172 - 180 °C 172 - 180 °C 

Vicat softening 

temperature B/50 

Vicat softening 

temperature A/50 

Heat conductivity 0.5 - 0.8 W(mK) -1 

Glass Transition 

Temperature 

Material 

Destruction 

Remaining Ash 

Content 

169 °C 163 °C 166 °C 

181 °C 179 °C 

150 ± 1 °C 

250 - 550 °C 

0.002 % 

Be prepared 

Boy Scout Motto

W H A T I S D M L S ? 

What is Direct Metal Laser Sintering? 

Direct Metal Laser Sintering (DMLS) is a 

revolutionary technology that produces otherwise 

‘impossible-to-make’ end-use metal parts 

directly from your 3D CAD data, whilst negating 

the investment in time and money of conventional 

tooling. 

The parts produced are comparable to 

a good investment cast part and the mechanical 

properties are comparable to those of a cast or 

machined component. 

The DMLS process is not restrictive in its application 

and the components produced can be used in place 

of almost any conventionally manufactured part, 

whether they would normally 

be machined or cast. 

The 

advantage of the process is 

that the more complex or 

feature rich the component, 

the more economical the 

process becomes. 

DMLS is an ‘additive’ 

technology that works by 

fusing together very fine 

layers of metal powder using 

a focussed laser beam. 

www.3trpd.co.uk/dmls 

A 

support structure is required 

CAD Model 

Sintered Part 

to hold the parts in position during building and this 

is anchored onto a steel platform. The supports and 

components are built with a layer thickness ranging 

from 20 to 60 microns depending on the material 

used. Each layer is scanned with the laser fusing the 

powder to layer below and forming the new build 

layer, the base is lowered one layer, a fresh layer of 

powder is deposited, and the next layer is scanned. A 

powerful 200W Yb-fibre laser is precisely controlled 

in the X and Y co-ordinates allowing for exceptional 

tolerances to be held (

F I N I S H I N G O P T I O N S 

What are the finishing options? 

Metal parts can be supplied ‘asbuilt’ 

or finished using various post processing and 

finishing techniques by our team of expert finishers. 

Dependant upon the material used, there are various 

forms of finishing available:- 

Shot-peening is a cold working process used to 

produce a compressive residual stress layer and modify 

mechanical properties of metals. It entails impacting a 

surface with shot (round metallic or ceramic particles) 

with force sufficient to create small indentations or 

dimples. 

It is similar to sandblasting, except that it 

operates by the mechanism of plasticity rather than 

abrasion: each piece of shot striking the material acts 

as a tiny peening hammer. In practice, this means that 

less material is removed by the process, and less dust 

created. Shot peening may be used for cosmetic effect. 

The surface roughness resulting from the overlapping 

dimples causes light to scatter upon reflection. 

Because peening typically produces larger surface 

features than sand-blasting, the resulting effect is 

more pronounced. 

Part in Cobalt Chrome 

shot-peened with Metal 

Part in Cobalt Chrome shotpeened 

with Metal & Ceramics 

Metal Polishing is the process of smoothing metals 

and alloys and polishing to a bright, smooth, mirrorlike 

finish. This can enhance the aesthetic appearance 

of parts as well as preventing corrosion, particularly 

those being used in automotive and aerospace 

environments. Medical instruments can also be highly 

polished to maintain hygienic conditions and prevent 

contamination in marks in the metals. 

Polishing is a metal-finishing operation where articles 

are polished using abrasives or mops, in a multistage 

process. Firstly, coarse grit abrasives are applied at 

high speed to remove surface defects like pits, nicks, 

lines and scratches. Then fine grit abrasives are used 

to remove the residue and smooth the surface. Finally, 

cotton mops are used to give a mirror-like finish to 

the articles. Lubricants such as wax, diesel fuel and 

kerosene are used as lubricating and cooling media 

during these operations. Sophisticated computercontrolled 

machines can be used to polish intricately 

shaped articles, although much of this work can also 

be carried out by hand. 

Examples of finished DMLS parts, highly polished 

Ask the experienced rather than the learned 

Arabic Proverb

D M L S A P P L I C A T I O N S 

Applications for DMLS 

DMLS is fast becoming a recognised 

manufacturing method for the fast, accurate 

production of one-off prototype components or for 

the economical manufacture of small series parts for 

testing purposes, or as final products for use in many 

different environments. 

The process generates hard wearing but intricate 

components, opening up opportunities to all 

industries, including Aerospace, Automotive, 

Electronic and Medical, and for generating Tooling 

Inserts. Certain materials give the parts rigidity and 

weight, thereby making it attractive to the aerospace 

and automotive sectors for vigorous testing and use 

in a wind tunnel. The strength of the process makes it 

attractive to the medical sector, and the high levels of 

finishing produces parts that are sterile and hygienic. 

More and more industries are using physical models 

throughout their product development cycle, 

dramatically reducing their time to market and 

assisting them with:- 

• Communication of ideas 

• Investigating ergonomics 

• Functionality testing 

• Assembly trials 

• Market research 


• Wind tunnel testing 

The possible applications for Direct Metal Laser 

Sintering (DMLS) are very broad indeed but because 

the technology is so new, the extent to which it can be 

applied within different industries has not yet been fully 

explored. With the speed of the machines increasing 

all the time and the range of metals continuing to 

grow, the viable options and opportunities for their 

application will become more widely recognised. 

Current applications 

for DMLS beyond the 

stated industries are 

Jewellery, Dental, Art/ 

Sculpture and Marine/Yachting. 

As awareness of DMLS grows, so will the add-on 

applications associated with it. For example, the 

software written by “Complex Matters” that can 

create intelligent internal structures will enable the 

production of super-lightweight, ultra-high stiffness 

components. This is a field that has only just started 

to be investigated, and yet holds substantial potential. 

The software, developed by Dr Siavash Mahdavi, 

will revolutionise structural design over the coming 

years, and can maximise the capabilities of the DMLS 

process. 

To follow are 

some examples of how 

DMLS can assist some key industries that we 

work with, and as we find new applications 

for the technology, we will add them to 

our website.

R A P I D M A N U F A C T U R I N G 

Rapid Manufacturing 

The term ‘Rapid Manufacturing’ 

(RM) has been coined to describe the manufacture 

of end-use parts and components by additive 

layer technologies such as Selective Laser Sintering 

(SLS), Stereolithography (SLA) and the most recent 

process, Direct Metal Laser Sintering (DMLS). 

The principal advantage of making production 

parts directly using DMLS, is that there is no tooling 

required, and only a modest amount of machining 

and finishing. 98% of the powder not used to make 

the part is recycled and so the process is economical 

and environmentally friendly. 

Example of 

customisation for a 

patient’s individual 

requirements 

One notable feature of DMLS is that it is possible to 

create a part that has both external and internal 

complexity in one go. Not only does this mean that 

you can create highly functional parts, but you can 

potentially combine what would have been several 

parts into one, saving manufacture cost, reducing 

assembly time and increasing reliability. 

Parts can be labeled directly using DMLS, building a 

number or other identifier directly into the part, an 

important attribute for traceability. Because DMLS 

parts do not require tooling to make them, not only 

do you save on the tooling cost, but you can have 

as many or as few parts at a time as you want, saving 

on WIP inventory. You can even have small design 

variations for every single part and the DMLS process 

will treat them all in the same way. 

In effect, DMLS enables ‘Mass Customisation’. 

For 

example, each of us is very different, but we could all 

have individually fitted replacement joints based on 

a single generic design, but manufactured to suit our 

own sizes and shapes. 

Rapid Manufacturing example: bed of 

Aerospace parts built using DMLS 

When you go to buy, use your eyes, not your ears 

Czech Proverb

M E D I C A L A P P L I C A T I O N S 

Medical applications 

With the introduction of DMLS to the 

medical industry, the manufacture of patient 

specific instrumentation and implants has become cost- 

and time- effective. The DMLS process enables surgical 

and medical devices to be manufactured directly from 

the CAD design, without having to endure the cost 

elements of conventional manufacturing techniques. 

The reduction in leadtimes that this technology offers 

opens up new opportunities for custom devices to 

be designed and manufactured for trauma patients. 

Rather than using standard products, they can have 

the right tools and instruments to meet their specific 

requirements. 

Also suitable for production, DMLS enables the 

manufacture of implants and instrumentation for 

clinical trials. Without the need for tooling and with 

reduced leadtimes, the designs can remain fluent, 

adapting to the surgeons and patients’ 

requirements as they happen. 

In addition to surgical applications, 

the DMLS process can be used in the 

development and manufacture of 

medical equipment, as it gives the flexibility to 

produce low volume parts at an affordable price. All 

material properties meet the chemical and mechanical 

specifications of standard cast parts, so CE marking can 


be obtained while large volume production methods 

and tooling are being developed. 

Some suitable applications are:- 

• Cranial maxillofacial implants 

• Orthopaedic instruments and saw guides 

• Arthroscopy and key hole instruments 

• Custom devices 

• Medical apparatus 

• Analytical equipment 

• Demonstrations and training 

As more challenging and complex procedures are 

being carried out, the ability to inexpensively and 

efficiently produce customised devices and models is 

becoming increasingly attractive for many specialist 

areas within the medical sector. 

Several materials 

are already available for the medical industry; Cobalt 

Chrome alloy (EOS CC MP1), Dental Cobalt Chrome 

alloy (EOS CC SP2), Stainless Steel 15-5PH (EOS PH1) 

Medical devices in EOS 

StainlessSteel 17-4 

(Source: PEP/DePuy) 

and Ti6Al4V alloy (EOS Ti64). 

Examples of medical 

applications

F 1 & A E R E O S P A C E 

Formula 1 & Aerospace applications 

The DMLS process holds tremendous 

potential for Formula 1 and Aerospace. Not 

only can it produce complex and structurally 

challenging parts in various materials, but it can also 

offer leadtimes unachievable by other methods. 

DMLS enables production of very strong but 

lightweight parts by building them hollow or with 

an intelligent internal structure. Complex parts can 

also be produced that couldn’t be made any other 

way. For example, you can combine a number of 

parts into a single one, making it lighter and possibly 

improving the functionality and strength. 

3T can currently create parts in Cobalt Chrome alloy 

(EOS CC MP1), Stainless Steel 15-5PH (EOS PH1), 

Inconel 718 (EOS 718 Alloy) and Maraging Steel 

1.2709 (EOS MS1). The Inconel 718 Superalloy is 

probably the most attractive one for these markets, 

as it offers very high strength and hardness, and 

can withstand high operating temperatures. The 

material could be used to produce accurate, complex 

exhaust manifold forms for example, and other 

options may include gearbox parts, suspension 

parts or complex fixings. 

Automotive Exhaust 

Aerospace Fuel Injector 

Aerospace components 

(l) as built (r) polished 

Assystem Aerospace Casing 

To know the road ahead, ask those coming back 

Chinese Proverb

T O O L I N G A P P L I C A T I O N S 

Tooling applications 

The DMLS technology was originally 

developed to create complex cores and cavities 

for the prototype tooling industry. The initial 

machine (EOS M250) and materials (bronze DM20) 

were quite enhancing compared with other rapid 

prototyping technologies at the time and were the 

right answer for the quick production of a small series 

of parts. However, the ability to produce production 

tooling inserts has never been demonstrated with 

the initial machine. 

With the introduction of a new machine (EOS M270) 

with a new type of laser and new types of materials, it 

is now possible to envisage the use of this technology 

for the manufacturing of smarter production inserts 

for plastic, ceramic, metal injection moulding and 

die casting. Not only can high strength and hardness 

tool steel be used, but extra features such as 

conformal cooling, which will enable a more uniform 

distribution of temperature inside the inserts, can be 

added in the design of the tool at no extra cost. 

Prototype tooling 


Shorter leadtimes, increased productivity and better 

part quality can now be reached with the DMLS 

inserts. 

Die cast tool 

The design of DMLS tools is very different from 

the design of the same tool using conventional 

machining method and 3T will give you the best 

advice on how to design the right DMLS inserts. 

Plastic injection moulding pin 

with conformal cooling

3T’s DMLS Machines 

EOSINT M270 (3 off) - Metal Sintering Machine 

Laser Type: 

Layer Thickness (material-dependent): 

Yb-fibre laser, 200 W 

20 - 60 μm 

D M L S P L A N T L I S T 

Effective Building Volume (including building platform): 

Building Speed (material dependent): 2 - 20 mm 3 /s 

Scan Speed: 

Variable Focus Diameter: 

250mm x 250mm x 215mm 

up to 7.0 m/s 

100 - 500 μm 

DMC 835V - Vertical Machining Centre 

X- / Y- / Z-axis: 835 / 510 / 510 mm 

Speed range up to: 

12,000 rpm 

The DMC 835V is a highly versatile and multi-functional machine due to its proven and enhanced technical 

standards, maximum reliability, user-friendly handling and large work area. It is 20% faster to the finished 

workpiece, with state-of-the-art 3D software and reduced processing time with 30 rpm rapid traverse and 

short chip-to-chip times (5 seconds) with 1.6 second tool exchange time. 

Our DMLS facility 

Tomorrow belongs to the people 

who prepare for it today 

African Proverb

D M L S M A T E R I A L S 


DMLS Materials - Technical Specifications 

Ti64 Titanium alloy (EOS Ti64) 

EOS Titanium Ti64 is a pre-alloyed Ti6AlV4 alloy in fine powder form. This well-known light alloy is characterised by having excellent 

mechanical properties and corrosion resistance combined with low specific weight and biocompatibility. This material is ideal for many 

high-performance engineering applications, for example in aerospace and motor racing, and also for the production of biomedical 

implants. Parts built in EOS Titanium Ti64 fulfill the requirements of ASTM F1472 regarding maximum concentration of impurities. 

Standard processing parameters use full melting of the entire geometry. Parts built from EOS Titanium Ti64 can be machined, sparkeroded, 

welded, micro shot-peened, polished and coated if required. Unexposed powder can be re-used. 

Stainless Steel 15-5 PH (EOS PH1) 

EOS StainlessSteel PH1 is a pre-alloyed stainless steel in fine powder form. Its composition corresponds to US classification 15-5PH and 

European 1.4540 and fulfils the requirements of AMS 5659 for Mn, Mo, Ni, Si, C, Cr and Cu. This kind of steel is characterized by having 

very good corrosion resistance and mechanical properties, especially in the precipitation hardened state. This type of steel is widely used 

in variety of medical, aerospace and other engineering applications requiring high hardness, strength and corrosion resistance. 

This material is ideal for many part-building applications (DirectPart) such as functional metal prototypes, small series products, 

individualised products or spare parts. Standard processing parameters use full melting of the entire geometry with 20μm layer 

thickness, but it is also possible to use 40μm layer thickness to increase the build speed. Using standard parameters the mechanical 

properties are fairly uniform in all directions. Parts made from EOS StainlessSteel PH1 can be machined, spark-eroded, welded, micro 

shot-peened, polished and coated if required. Unexposed powder can be reused. 

Cobalt Chrome alloy (EOS CC MP1) 

EOS CC MP1 is a fine powder mixture which produces parts in a cobalt-chrome-molybdenum-based superalloy. This class of superalloy is 

characterized by having excellent mechanical properties (strength, hardness etc.), corrosion resistance and temperature resistance. Such 

alloys are commonly used in biomedical applications such as dental and medical implants and also for high-temperature engineering 

applications such as in aero engines. 

The chemistry of EOS CC MP1 conforms to the composition UNS R31538 of high carbon CoCrMo alloy. Parts built from this material are 

nickel-free (< 0.1% nickel content), sterilisable and suitable for biomedical applications, and are characterised by a fine, uniform crystal 

grain structure. They fully meet the requirements of ISO 5832-4 and ASTM F75 for cast CoCrMo implant alloys, as well as the requirements 

of ISO 5832-12 and ASTM F1537 for wrought CoCrMo implants alloys except remaining elongation. The remaining elongation can be 

increased to fulfill even this standard by hot isostatic pressing (HIP).This material is ideal for many part-building applications (DirectPart) 

such as functional metal prototypes, small series products, individualised products or spare parts. Using standard parameters the 

mechanical properties are fairly uniform in all directions. Parts made from EOS CC MP1 can be machined, spark-eroded, welded, micro 

shot-peened, polished and coated if required. Unexposed powder can be reused.


Dental Cobalt Chrome alloy (EOS CC SP2) 

EOS CC SP2 is a cobalt-chromemolybdenum-based superalloy powder which has been especially developed to fulfill the requirements of 

dental restorations which have to be veneered with dental ceramic material and has been optimised especially for processing on EOSINT 

M270 systems. 

EOS CC SP2 is a Co, Cr, Mo and W based alloy in fine powder form. Its composition corresponds for type 4 CoCr dental material in EN ISO 

22674:2006 standard. It also fulfills the chemical and thermal requirements of EN ISO 9693 for CoCr PFM (porcelain fused metal) of 

dental materials (Ni content: < 0.1 %, no Cd or Be) and requirements of EN ISO 7504, EN ISO10993-1:2003 and 10993-5:1999 regarding 

the biocompatibility and cytotoxity of the dental materials. This material is ideal for producing dental restorations. Standard processing 

parameters use full melting of the entire geometry with 20 Cm layer thickness. 

Maraging Steel 1.2709 (EOS MS1) 

EOS MS1 is a pre-alloyed ultra high strength steel in fine powder form. Its composition corresponds to US classification 18% Ni Maraging 

300, European 1.2709 and German X3NiCoMoTi 18-9-5. This kind of steel is characterised by having very good mechanical properties, and 

being easily heat-treatable using a simple thermal age-hardening process to obtain excellent hardness and strength. This material is 

ideal for many tooling applications such as tools for injection moulding, die casting of light metal alloys, punching, extrusion, and also 

for high performance industrial and engineering parts, for example aerospace and motor racing applications. 

Standard processing parameters use full melting of the entire geometry, typically with 40 μm layer thickness. Using standard parameters, 

the mechanical properties are fairly uniform in all directions. Parts built from EOS MS1 are easily machinable after the building process and 

can be easily post-hardened to more then 50 HRC by age-hardening at 490°C for 6 hours. In both as-built and age-hardened states the parts 

can be machined, spark-eroded, welded, micro shot-peened, polished and coated if required. Unexposed powder can be reused. 

Inconel 718 (EOS 718 Alloy) 

EOS 718 Alloy is a nickel based heat resistant alloy in fine powder form. Its composition corresponds to UNS N07718, AMS 5662, AMS 

5664, W.Nr 2.4668, DIN NiCr19Fe19NbMo3. This kind of precipitation-hardening nickel-chromium alloy is characterized by having good 

tensile, fatigue, creep and rupture strength at temperatures up to 700°C. 718 alloy has also outstanding corrosion resistance in various 

corrosive environments. 

This material is ideal for many high temperature applications such as gas turbine parts, instrumentation parts, power and process 

industry parts etc. Material also possesses excellent cryogenic properties and potential for cryogenic applications. 

Standard processing parameters use full melting of the entire geometry, typically with 20 µm layer thickness. Parts built from EOS 718 

Alloy can be easily post-hardened to 40-47 HRC (370-450HB) by precipitation-hardening heat treatments. In both as-built and agehardened 

states the parts can be machined, spark-eroded, welded, micro shot-peened, polished and coated if required.


Direct Metal - Bronze (EOS DM20) 

DirectMetal 20 is a very fine-grained bronze-based, multi-component metal powder. The resulting parts offer good mechanical properties 

combined with excellent detail resolution and surface quality. The surfaces can be easily post-processed by shot-peening and can be polished 

with very little effort. The specially developed powder mixture contains different components which expand during the laser-sintering 

process, partially compensating for the natural solidification shrinkage and thereby enabling a very high part accuracy to be achieved. 

This material is ideal for most prototype injection moulding tooling applications (DirectTool) and for many functional metal prototype 

applications (DirectPart). It offers the highest building speed and thus is particularly suitable for larger tools and parts. It also offers 

a broad window of usable process parameters, e.g. a wide range of achievable mechanical properties and build speeds. Standard 

parameters use 20 µm layer thickness for the skin and 60 µm layers for the core, but for faster building the entire part can be built using 

40 µm layers for the skin and 80 µm layers for the core. 

Using standard skin parameters the mechanical properties are fairly uniform in all directions, which is especially beneficial for many 

DirectPart applications. Areas built with core parameters have a porous structure, but the combination of skin and core produces a 

strong total part. Parts built from DirectMetal 20 also have good corrosion resistance.

Source: EOS 

Technical Data 

DMLS Materials - Technical Specification 

Ti64 Titanium alloy (EOS Ti64) 

Physical & Chemical properties 

Minimum recommended layer thickness 30 µm Relative density with standard parameters approx. 100% (4.43 g/cm 3 ) 

Minimum wall thickness 

0.8 mm 

Volume rate ~3 mm 3 /s 

Mechanical properties at 20 0 C 

(vertical orientation) 

Ultimate tensile strength 

Yield strength (Rp 0.2%) 

After stress-relieving 

1150 MPa + 60 MPa 

1030 MPa + 70 MPa 

Elongation at break 11% + 2% 

Young’s Modulus 

Hardness 

110 GPa + 7 GPa 

414 + 15 HV 

Surface roughness 

- after shot-peening approx. R a 

4 µm 

Thermal properties 

Maximum operating temperature 350°C 

Typical applications 

• Direct manufacture of functional prototypes, small series products, individualised products or spare parts 

• Parts requiring a combination of high mechanical properties and low specific weight, e.g. structural and engine components 

for aerospace and motor racing applications, etc. 

• Biomedical implants 

Stress relieving procedure: 

Stress relieving is done in a stress relieving furnace under argon atmosphere or in a vacuum furnace. The stress relieving sequence is 

as follows:- 

1. ramp up to 650 °C in 60 minutes 

2. hold for 3h 

3. furnace heating power off and open the furnace door when temperature dropped down to approx. 400°C 

Annealing: 

Material composition: 

Ti 

Al 

88.4-91.0 wt% 

5.5-6.5 wt% 

O 2 

N 

V 3.5-4.5 wt% C 

< 2000 ppm 

< 500 ppm 

< 800 ppm 

Specific properties can be modified by annealing the parts at various temperatures ranging from 650 to 850°C and for dwell times 

between 1 and 4h. 

H 2 

Fe 

< 120 ppm 

< 2500 ppm


Stainless Steel 15-5 PH (EOS PH1) 





Volume rate 

0.4 mm 

between 

1.8-3.2 mm 3 /s 


Mechanical properties at 20 o C As built After age-hardening* 

Ultimate tensile strength (MPIF 10) 

- horizontal direction (XY) 

- vertical direction (Z) 




Elongation at break 



1150 MPa + 50 MPa 

1050 MPa + 50 MPa 

1050 MPa + 50 MPa 

1050 MPa + 50 MPa 

16% + 4% 

17% + 2% 

1450 MPa + 100 MPa 

1450 MPa + 100 MPa 

1300 MPa + 100 MPa 

1300 MPa + 100 MPa 

12% + 2% 

12% + 2% 

Hardness 30-35 HRC Min 40 HRC 


- after shot-peening 

- after polishing 


Coefficient of thermal expansion 

(20-500ºC) 

Thermal conductivity (at 20ºC) 



R a 

4.5 µm 

R z 

up to < 0.5 µm 

12.5µm/m°C 

13.8 + 0.8 W/m°C 

13.7 + 0.8 W/m°C 

15.7 + 0.8 W/m°C 

15.8 + 0.8 W/m°C 

Specific heat capacity 

- as laser sintered 460 + 20 J/kg°C 470 + 20 J/kg°C 

Maximum operating temperature 550°C 550°C 


Fe 

Cr 

Ni 

71.5-80 wt% 

14-15.5 wt% 

3.5-5.5 wt% 

• Engineering applications including functional prototypes, small series products, individualised products or spare parts. 

• Parts requiring high corrosion resistance, sterilisability, etc. 

• Parts requiring particularly high hardness and strength. 

Cu 

Mn 

Si 

2.5-4.5 wt% 

max 1 wt% 

max 1 wt% 

Mo 

Nb 

C 

max 0.5 wt% 

0.15-0.45 wt% 

max 0.07 wt% 

* Age hardening modified H900: 482 ºC / 4h / air cooling 

Source: EOS



Cobalt Chrome alloy (EOS CC MP1) 




Volume rate 


Ultimate tensile strength (MPIF 10) 






Elongation at break 



- after HIPping 




Fatigue life* 

- in vertical direction (Z) at 0-400 MPa load 

range and 20Hz 

Hardness (DIN EN ISO 6508-1) 






- over 20-500°C 

- over 500-1000°C 

Thermal conductivity 

0.4 mm 

between 

1.6-3 mm 3 /s 

1300 MPa + 50 MPa 

1150 MPa + 50 MPa 

980 MPa + 50 MPa 

880 MPa + 50 MPa 

11% + 2% 

9% + 1% 

21-24% 

220 GPa + 20 GPa 

220 GPa + 20 GPa 

approx. 7.2 million cycles 

40-45 HRC 


Melting range 


approx. R a 

10 µm 

R 

z 

up to < 1 µm 

13.6 x 10 -6 m/m°C 

15.1 x 10 -6 m/m°C 

at 20°C - 13 W/m°C. at 300°C - 18 W/m°C. at 500°C - 22 W/m°C. at 1000°C - 33 W/m°C 

1350-1430°C 


Co 60-65 wt% 

Cr 26-30 wt% 

Mo 5-7 wt% 

• Biomedical implants, e.g. spinal, knee, hip bone, toe, etc. 

• Parts requiring high mechanical properties in elevated temperatures (500 - 1000 °C) and with good corrosion resistance, e.g. 

turbines and other parts for engines, etc. 

• Parts having very small features such as thin walls, pins, etc., which require particularly high strength and/or stiffness. 

* Tested using round fatigue bar of approx. 4mm smallest diameter in neck region, 6mm diameter at the ends and 

50mm total length. Neck regions smoothed by sand paper prior to testing. 

Si 

Mn 

Fe 

max 1 w% 

max 1 wt% 

max 0.75 wt% 

C 

Ni 

max 0.16 wt% 

max 0.1 wt% 

Source: EOS

Source: EOS 


Dental Cobalt Chrome alloy (EOS CC SP2) 





Volume rate 



As built 

After stress-relieving 

Ultimate tensile strength (MPIF 10) 1050 MPa + 250 MPa 1100 MPa + 100 MPa 

Yield strength (Rp 0.2%) 750 MPa + 150 MPa 900 MPa + 80 MPa 

Elongation at break 14% 10% 

Young’s Modulus 200 GPa + 30 GPa 200 GPa + 10 GPa 

Hardness HV10 360-30 HV 340-30 HV 


- after shot-peening approx. R a 

4 µm 



- over 20-500°C 14.0-14.5 x 10 -6 m/m°C 

Melting range 


• Dental restorations (crowns, bridges, etc..) 

Stress relieving procedure:- 

0.4 mm 

between 1.98- 

2.2 mm 3 /s 


Co 61.8-65.8 wt% 

Cr 23.7-25.7 wt% 

Mo 4.6-5.6 wt% 

1380-1440°C 

Stress relieving is done in a stress relieving furnace under argon atmosphere. 

The stress relieving sequence is as follows:- 

W 

Si 

Fe 

4.9-5.9 wt% 

0.8-1.2 w% 

max 0.5 wt% 

Mn max 0.1 wt% 

Use the 1-2 l/min Ar flow into protective gas box 


2. holding for 45 minutes 


4. holding for 60 minutes 

5. furnace heating power off and open the furnace door when temperature dropped down to approx. 600°C 

6. remove the protective gas box when furnace has cooled down to approx. 300°C and shut down the argon flow

Source: EOS 



Maraging Steel 1.2709 (EOS MS1) 


Minimum recommended layer thickness 40 µm Relative density with standard parameters approx. 100% (8 g/cm 3 ) 

Minimum wall thickness 0.4 mm Material composition: 

Volume rate 

between 

2-4 mm 3 /s 

Age hardening shrinkage* 0.08% 

Mechanical properties at 20 o C 


As built 

After age-hardening* 

Ultimate tensile strength (MPIF 10) 1100 MPa + 100 MPa 1950 MPa + 100 MPa 

Yield strength (Rp 0.2%) 1000 MPa + 100 MPa 1900 MPa + 100 MPa 

Elongation at break 8% + 3% 2% + 1% 


180 GPa + 20 GPa 

Hardness 33-37 HRC 50-54 HRC 

Ductility 

(Notched Charpy Impact Test) 





45 J + 10 J 11 J + 4 J 

R a 

4-6.5 m 

R 

z 


Thermal conductivity (at 20 0 C) 15 + 0.8 W/m o C 20 + 1 W/m o C 

Specific heat capacity 450 + 20 J/kgm o C 450 + 20 J/kgm o C 



• Heavy duty injection moulds and inserts for moulding all standard thermoplastics using standard injection 

parameters, with achievable tool life of up to millions of parts. 

• Die casting moulds for small series in light alloys. 

• Parts requiring particularly high strength and hardness. 

Fe 

Ni 

Co 

64.6-69.35 wt% 

17-19 wt% 

8.5-9.5 wt% 

Mo 

Ti 

Al 

Mn, Si - each max 0.1 wt% 

4.5-5.2 wt% 

0.6-0.8 wt% 

0.05-0.15 wt% 

Cr 

C 

max 0.5 wt% 

max 0.03 wt% 

P, S - each max 0.01 wt% 

* Age hardening: 490 ºC / 6h / air cooling



(vertical position) 


Inconel 718 (EOS 718 Alloy) 

As built After heat-treatment 1 After heat-treatment 2 

Ultimate tensile strength (MPIF 10) 980 MPa + 50 MPa 1400 MPa + 100 MPa 1384 MPa + 100 MPa 

Yield strength (Rp 0.2%) 634 MPa + 50 MPa 1150 MPa + 50 MPa 1239 MPa + 100 MPa 

Elongation at break 31% + 3% 15% + 3% 15% + 3% 


170 GPa + 20 GPa 

Hardness ~ 30 HRC ~ 47 HRC ~ 43 HRC 





Thermal conductivity (at 20°C) 

Specific heat capacity 

R a 

4 - 6.5 µm 

R 

z 


TBC 

TBC 

Maximum operating temperature Under load 650°C 

Oxidation resistance up to 980°C 


• Aero and land based turbine engine parts. 

• Rocket and space application components. 

• Chemical and process industry parts. 

• Oil well, petroleum and natural gas industry parts. 



Minimum wall thickness 0.4 mm Material composition: 

Volume rate 2 mm 3 /s 

Age hardening shrinkage* 

TBC 

Ni 

Cr 

Fe 

50-55 wt% 

17-21 wt% 

11.13-24.6 wt% 

1 

Age heat-treatment according to AMS5662:- 

Step1. Solution Anneal at 980°C for 1 hour, air (/argon) cool. 

Step 2. Ageing treatment; hold at 720°C 8 hours, furnace cool to 620°C in 2 hours, hold at 620°C 8 hours, air(/argon) cool. 

2 

Age heat-treatment according to AMS5664:- 

Step1. Solution Anneal at 1065°C for 1 hour, air (/argon) cool. 

Step 2. Ageing treatment; hold at 760°C 10 hours, furnace cool to 650°C in 2 hours, hold at 650°C 8 hours, air(/argon) cool. 

Nb 

Mo 

Ti 

Mn, Si - each max 0.35 wt% 

4.75-5.5 wt% 

2.8-3.3 wt% 

0.65-1.15 wt% 

Al 0.2-0.8 wt% 

Co max 1 wt% 

B max 0.006 wt% 

P, S - each max 0.015 wt% 

Under normal process conditions, all the parts will be built using Argon. 

Source: EOS

Source: EOS 


Minimum recommended layer thickness 20 µm 



Direct Metal - Bronze (EOS DM20) 

0.6 mm 

Volume rate between 10-20 mm 3 /s 


Remaining porosity 8% 

Tensile strength (MPIF 10) 

Yield strength 


Hardness 





up to 400 MPa 

200 MPa 

80 GPa 

120 HV 

R a 

3 µm 

R z 

< 1 µm 

Coefficient of thermal expansion 18 x 10 -6 /K 

Thermal conductivity (at 50 o C) 

Maximum operating temperature 


30 W/mK 

400 o C 

• Injection moulds and inserts for moulding up to tens or even hundreds of thousands of parts in standard 

thermoplastics using standard injection parameters. 

• Direct manufacture of functional metal prototypes.

How There are various ways in which you can send us your 3D CAD data for quotation; the easiest and 

quickest is to attach it to an email and send it to post@3trpd.co.uk. Alternatively, you may complete our secure 

online Request a Quote form with all the relevant details of your quote requirement and attach your data, which 

is then sent to us via email. 

do I send you my data?File Size: Whilst our server can easily allow up to 10MB through without 

D A T A T R A N S M I S S I O N 

If your data files are too large to send via email, you can upload them to our FTP (File Transfer Protocol) site; an easy to 

use and totally secure way of exchanging files over the internet. Simply call our Projects Team and they will email you a 

free download of the Core FTP software, together with instructions on how to upload your files. 

We always endeavour to email you a quotation within 24 hours. 

Data Formats: There are a number of CAD systems we use and many different file types that we can read, as follows:- 

Universal Translators .STL Rapid Prototyping file (Binary with 0.01mm tolerance preferred) 

.IGES Initial Graphics Exchange Specification universal translator 

.STEP International Standard for Exchange of Product Model Data 

.VDA Surfaced Data Interface V2.0 

.X_T Parasolid 

The .STL and .IGES file formats have become 

Native CAD files 

.OBJ 3D Object 

the standard data transmission method for 

.WRL VRML (Virtual Reality Modelling Language) the Rapid Prototyping industry, with .STL 

being the preferred format to build SLS 

.SLDPRT Solidworks model file 

parts, and .IGES for DMLS parts. Almost 

.EXP Catia V4 export file 

all of today’s CAD systems are capable 

.MDL Catia V4 native file 

of producing .STL and .IGES files and the 

.PRT Pro/Engineer 

process is often as simple as selecting File, 

.PRT Unigraphics 

Save As, .STL/.IGES. 

2D image files 

.3DS 3D Studio 

.3DM Rhino file 

* Whilst we can generate a quotation from 

almost any data source, we can only build 

.BMP Windows Bitmap image format file* 

from those that are 3D. File types that are 

.JPEG Joint Photographic Experts Group image file* 2D do not include sufficient information to 

.TIFF Tagged-Image File Format image file* 

drive the modeling process, and therefore a 

PDF Adobe Acrobat document* 

2D-3D conversion is required. 

CAD Systems currently in use at 3T:- 

SolidWorks 

PTC Pro/Engineer Wildfire 1 

Materialise Magics RP 

Materialise 3-Matic 

Rhinoceros V3.0 

For further information on how to generate a good .STL 

file, visit our website and go to the Technical Data section. 

any problem, it is important that your data files are compacted to allow 

them to be successfully e-mailed and quickly downloaded so that you 

can receive your quotation as quickly as possible. Therefore, files should 

be zipped before sending and Stlzip software is a very efficient means of 

doing this - a free copy can be emailed to you upon request. 

Never squat with your spurs on. 

Texan Proverb

C O N T A C T U S 

3T RPD Ltd 

Fulton Court 

Wofford Way 

New Greenham Park 

Newbury 

Berkshire 

RG19 6HD 

UK 

Ian Halliday, CEO 

Stuart Offer, Sales Manager 

Bruno Le Razer, DMLS Research & Applications 

Phil Kilburn, Medical Markets Manager 

Trevor Howarth, Technical Sales Engineer 

Martin McMahon, DMLS Account Manager 

Ray Neal, SLS Account Manager 

Hannah King, Projects Manager 

Main Website: 


DMLS: 


Architecture: 

www.3trpd.co.uk/architecture 

T. +44 (0)1635 580284 

F. +44 (0)1635 569857 

E. post@3trpd.co.uk

Tell me and I’ll forget. 

Show me, and I may not remember. 

Involve me, and I’ll understand. 

Native American Proverb 

www.3trpd.co.uk

DMLS Materials - Technical Specifications

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