Metal 3D Printing in 2025: DMLS vs. Binder Jetting Explained

The face of metal manufacturing has changed. No longer a distant futuristic experiment in 2025, metal 3D printing has taken a foothold as a cornerstone of industrial production. Yet, in parallel to maturity, the now-ubiquitous question that every business and engineer really wants to ask is, well: Which metal 3D printing service is best for my project?

These are the heavyweights in the arena: Direct Metal Laser Sintering (DMLS) and Metal Binder Jetting (BJT). Both create these complex metal parts still, they operate on completely different principles, and choosing the wrong one will lead to unnecessary cost or failure under pressure.

At Norck, we guide our customers through such technical crossroads day in and day out. This guide demystifies the differences between DMLS and Binder Jetting so you can make an informed decision for your 2025 production cycle.

Understanding the Technologies

What is DMLS?

"The gold standard of high performance metal parts," Direct Metal Laser Sintering (DMLS) is a technology that delivers a powerful fiber laser to melt and bond layers of metal powders precisely. Since it requires complete melting of metal, DMLS-produced parts are very dense and dense, and, at times, this surpasses those of cast or forged metals.

What is Binder Jetting?

Binder Jetting can be characterized as a "high speed" metal 3D printing service. It relies not on a laser but rather on a print head to apply a liquid binding agent to a layer of metal powder, effectively "sticking" it all together. After completion of printing, it is left in a "green" state, meaning it is brittle and can only be fired into a furnace to be sintered.

1. Strength and Material Integrity

When it comes to mechanical performance, DMLS has the upper hand. Because the laser creates a full metallurgical bond during the print, the parts are nearly 100% dense and isotropic.

• DMLS: Ideal for "end-use" functional parts in aerospace, medical, and automotive sectors.

• Binder Jetting: Although the sintering process results in a strongly bonded component, a degree of porosity is usually always produced, which is only able to reach 95% to 98% density. This is still not sufficient for other uses, such as a jet engine turbine and an aerospace bracket.

2. Speed and Scalability

This is where Binder Jetting shines. In 2025, Binder Jetting is the preferred choice for companies moving from "prototyping" to "mass production."

• DMLS: The laser needs to draw literally every single detail in every part. This means if you have a full tray of components, then your build time increases linearly. This makes DMLS better suited for small batches of highly complex parts.

• Binder Jetting: The print head covers the entire bed in a single pass, laying binder for dozens of parts at once. It can print a full build volume in a fraction of the time it takes DMLS. If you need 500 metal brackets by next week, Binder Jetting is most likely your most efficient path.

3. Precision and Surface Finish

If your design has tiny internal channels (like conformal cooling in molds) or requires extreme dimensional accuracy, DMLS is the winner.

• DMLS: The laser is incredibly fine, allowing for "tight" tolerances and sharp details. The surface finish is consistent, appearing like a fine-grit sandpaper.

• Binder Jetting: Parts shrink significantly during the furnace sintering process - sometimes by as much as 15% to 20%.

4. Cost Considerations

As a business owner or procurement manager, the bottom line is often the deciding factor.

• DMLS: Generally has a higher cost per part. This is due to the high energy consumption of the lasers, the requirement for support structures that must be manually removed, and slower throughput.

• Binder Jetting: Much lower cost for high volumes. Because it is faster and doesn't require support structures the "price per part" drops significantly as you increase your order quantity.

5. Post-Processing Requirements

Metal 3D printing services are far from over once the printer has finished a project.

• DMLS: The parts are welded to the metal build plate. They need "supports" to prevent the warping effect brought by the heat. The removal of those "support" structures can only be accomplished through manual labor, wire EDM, or CNC machining.

• Binder Jetting: Since they are supported by loose powdery material, they can print without needing print supports. However, they do involve an additional process of furnace sintering, which is essential and takes a number of hours, and you can also need hot isostatic pressing if you want to achieve 100% density.

Conclusion: Which One Do You Need?

While in 2025, DMLS vs. Binder Jetting is left to the objectives of your project:

• Choose DMLS: If you need high-performance, aerospace-grade components, medical implants with certified biocompatibility, or parts featuring complex internal lattice structures that have to support extreme pressure.

• Binder Jetting: If you need series production of 50 to 5,000 parts with the drive of reducing "cost-per-unit" in large batches of functional industrial components with slight porosity acceptable.

Norck doesn't believe in a "one-size-fits-all" approach. Our manufacturing platform analyses your CAD data and requires volume to suggest the most efficient path. Our team ensures your parts are delivered at the highest quality standards.

Contact us today, and one of our professional engineers will help you decide which metal additive technology is right for your 2025 production goals.