Metal SLM prototype series — how it runs

A typical brief

An engineering team needs a small series of structural aluminium parts to validate a mechanical assembly before committing to tooled production. The geometry includes internal channels that CNC machining alone cannot reproduce, and there is a testing window to hit.

When metal printing is the right choice

Three factors point away from traditional manufacturing and toward Selective Laser Melting (SLM):

Internal channels — integrated fluid passages that cross through the part body. Impossible to machine without splitting and rejoining, which would have compromised structural integrity.
Geometry complexity — organic, load-optimized shape that was designed for additive manufacturing from the start.
Low quantity, high value per part — at a handful of parts, tooling costs more than the parts themselves.

Process

DfAM review — a call to review the CAD and flag geometry that fights the process (overhangs, thin walls, support-trapped cavities), with suggested adjustments.
Material selection — AlSi10Mg (aluminum-silicon alloy) for the combination of strength, weight, and post-T6 heat treatability.
Build — parts printed by our partner in a single build with support structures optimized for minimal post-processing.
Post-processing — support removal, stress relief, T6 heat treatment, bead blasting, and a dimensional inspection report.
Handover — finished parts shipped with an inspection report against the CAD model.

What to expect

10–20 working days of production from order confirmation, plus shipping. The quote states the exact date.
An inspection report against your CAD with the delivered parts.
One point of contact from DfAM review to delivery.

Key takeaways for engineers evaluating metal 3D printing

Metal printing is not a replacement for machining — it is a complement. Pick it when geometry demands it or when lead time and low quantity make tooling uneconomical.
Design for AM early. Parts designed for subtractive methods and converted later rarely perform well. The best results come from geometry conceived for the process.
Post-processing matters. Heat treatment and surface finish can change mechanical properties significantly. Plan them into the spec from the start.
Budget for QA. A dimensional inspection report is not a luxury — it is how you know the part you are testing matches the digital design.

Have a similar project?

We offer a free 30-minute DfAM review for any metal 3D printing project. We will look at your geometry, flag potential issues before you commit, and give you a realistic budget and lead time range.

Get in touch or read more on the 3D printing service page.