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[Anna S.]

I’m testing the idea of using DMLS Aluminum parts as pre-production prototypes for a high-pressure fluid system. These would be static housings only, not moving parts. Has anyone validated 3D-printed aluminum components under realistic pressure and temperature loads? Curious how close the material behavior and tolerances are to machined aluminum in practice.

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[Theresa B.]

Using DMLS aluminum parts is becoming a common step before full-scale machining, but there are areas you need to treat with caution. DMLS components can handle realistic pressure and temperature loads, but only if the printing is top quality, from a really reliable supplier/operator. When hot isostatic pressed, the T6 or equivalent heat-treated AlSi10Mg can achieve 90–95% of the tensile and yield strength of wrought 6061-T6. Fatigue performance is poorer, however. Remember that you cannot typically certify DMLS-made parts. You’ll also need to specify CNC machining of critical sealing or gasket surfaces to deliver seal-capable dimensional accuracy.

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