Direct metal laser sintering: Material considerations and mechanisms of particle bonding

Most of the rapid prototyping processes wit a high potential for the fabrication of metal or ceramic parts involve powder materials. Direct metal laser sintering is now an established method for the production of functional prototypes and mold inserts using computer-controlled laser/scanning with a powder feed system. The characteristics of the powder materials and the processing parameters influence the properties of prototypes and tools. This article addresses material considerations in the direct metal laser sintering process. Mechanisms of particle bonding and resulting microstructural features are described and the influence of manufacturing parameters and the basic principles of the process are delineated.