Direct metal laser sintering (DMLS) is a metal 3D printing technique that spreads a thin layer of metal powder uniformly over a building plate. It is fused, layer by layer, with a high-powered laser until the final geometry is formed. The powder bed is kept at elevated temperatures to optimize sintering conditions. DMLS machining is ideal for producing robust, complex metal parts with minimal waste. 

What it’s best used for: 

• lightweight parts for aerospace
• medical devices
• automotive components
• Other aerospace, automotive, medical, defense and energy applications

Selective laser sintering (SLS) additive manufacturing uses high-powered lasers to fuse powdered plastic polymers layer by layer, creating durable and complex 3D objects. The material options — ranging from nylon to glass-filled composites — allow for versatile part characteristics. SLS printing machines can be used for functional prototypes, production-grade end-use parts and specialized tooling.

What it’s best used for: 

• Low- to mid-volume runs of plastic components 
• Medical models
• Complex housings 
• Other consumer products, health care, robotics and electronics applications

Fused filament fabrication (FFF) involves extruding thermoplastic material through a heated nozzle, and depositing it layer by layer to form the final part. This method can be ideal for cost-effective, rapid production of jigs, fixtures and functional prototypes.

What it’s best used for: 

• Prototyping
• Small-batch production
• Support tooling
• Other education, automotive and consumer products applications

Fused deposition modeling (FDM) 3D printing is often considered an industrial or proprietary version of FFF. FDM 3D printing manufacturing typically offers a higher level of precision, material variety and automated post-processing options. Many high-performance thermoplastics, including those reinforced with carbon fibers, can be used in FDM systems for strength-critical applications.

What it’s best used for: 

• End-use parts
• Tooling aids
• Functional prototyping 
• Other automotive, aerospace and product development applications

Direct energy deposition (DED) uses focused thermal energy, such as lasers or electron beams, to deposit material (usually metal powder or wire) precisely where it is needed. DED is commonly used when repairing high-value metal components because of its ability to work on large parts and significant cost savings.

What it’s best used for:

• Component repair
• Adding to existing components
• Manufacturing large-scale metal parts
• Other aerospace, heavy equipment, energy and tooling applications

Stereolithography (SLA) and direct laser projection (DLP) use photopolymer resins cured by a laser (SLA) or projected light (DLP) to achieve high-resolution features and exceptionally smooth surface finishes.

What it’s best used for: 

• Visual prototypes
• Medical models
• Intricate jewelry designs
• Other medical, jewelry and product design and research and development applications