SLM (Selective Laser Melting) is the most advanced metal-printing technology today. A laser locally melts metal powder layer by layer, producing a fully dense part (99.5%+) with mechanical properties matching or exceeding machined equivalents.
Aerospace applications
Aerospace adopted SLM faster than any other industry. The reason is simple: every gram of weight costs money over the vehicle’s lifetime. Design for Additive Manufacturing (DfAM) saves up to 50% in weight versus a traditional part.
- Complex cooling channels inside turbine blades
- Structural brackets in Titanium Ti-6Al-4V
- Engine parts in Inconel 718 that withstand 700°C+
Medical applications
In medicine, SLM enables patient-specific implants tailored to anatomy from CT or MRI scans. Titanium is biocompatible, and lattice structures promote bone ingrowth.
- Patient-specific spinal implants
- Hip and knee crowns in CoCrMo
- Surgical guides in 316L stainless
Challenges to know about
SLM is not free: thermal stresses produce internal residual stress, heat treatment is required post-print, and the surface finish is grainy and often needs supplementary machining. Smart design from the CAD stage saves time and money downstream.
When SLM pays off
When the geometry is too complex for traditional machining, when aggressive weight reduction is required, or for small series (1-50 units) where tooling can’t be justified. In other cases, CNC remains more economical.