Six alloys cover the vast majority of DMLS production. The selection framework is straightforward when framed around performance requirements rather than material familiarity.
Decision Hierarchy
- Temperature: Above 400°C sustained? → Inconel 718. Below 400°C → Ti6Al4V or steel.
- Weight: Below 5 g/cm³ required? → Ti6Al4V (4.43) or AlSi10Mg (2.67).
- Strength: Above 1,000 MPa UTS? → Ti6Al4V, 17-4 PH H900, or CoCrMo.
- Biocompatibility: Implantable or skin-contact? → Ti6Al4V ELI or CoCrMo.
- Corrosion: Aggressive aqueous environment? → 316L.
- Cost: Price-sensitive? → AlSi10Mg or 316L (lowest powder cost).
Material Data Reference
| Alloy | UTS (MPa) | Density (g/cm³) | Best Application |
|---|---|---|---|
| Ti6Al4V | 993–1,055 | 4.43 | Aerospace, medical |
| 17-4 PH SS | 1,365–1,372 | 7.78 | Tooling, structural |
| 316L SS | 565–586 | 7.99 | Corrosion, medical |
| AlSi10Mg | 268–345 | 2.67 | Lightweight structures |
| Inconel 718 | 958 | 8.19 | High-temperature |
| CoCrMo | 1,213–1,255 | 8.30 | Implants, wear |
Data from Proto Labs production and EOS material datasheets.