Advantages

• Direct metal printing: DMLS and SLM can produce metal parts directly. DMLS can be used with metal alloys or pure metals without affecting the properties of the material. Even mixtures of powders (e.g. aluminum and nylon) can be successfully printed.
• Variety of materials: Between DMLS and SLM, a wide range of metal and metal alloy powders are available, including steels, stainless steels, aluminum, titanium, nickel alloys, cobalt chrome, and precious metals.
• Strong, functional parts: The properties of a finished part are comparable to a part cast in the same material. Strong, functional metal parts are produced by the DMLS process. SLM can produce a stronger part by melting the metal. Final parts have good mechanical properties in all directions. (Some 3D printing methods — e.g. FDM — tend to be weak in at least one direction.)
• Recyclable material: Metal powder that is not sintered or melted is reusable.

Limitations

• High pricing: DMLS and SLM have the highest price points of 3D printing processes; the machines and materials are expensive, and the process is slow.
• Porous parts: Finished DMLS parts are porous relative to a melted metal part. Porosity can be controlled but not eliminated in the process or during post-processing.
• Small parts: Most DMLS printers have relatively small build volumes.

Design Recommendations

Overhangs with an angle greater than 35 degrees can be built without support structures.

Superfluous volumes should be avoided when using this technology

Overall, the most ideal geometries are small, self-supporting parts that would be difficult to manufacture through machining