Revealed: The Revolutionary Ultra SLM Metal 3D Printing Technology by Dream3D — Now Open for Collaboration

Recently, Dream3D, a Shenzhen-based company, unveiled a groundbreaking Ultra SLM (Selective Laser Melting) metal 3D printing technology that increases printing speed by 5–30 times, reduces manufacturing costs by over 30%, and boosts productivity by 10×. But how exactly does it achieve such remarkable gains? What makes this new process different? And why is it a startup like Dream3D leading this revolution?

Ultra SLM: A Leap Forward in Metal 3D Printing Performance

According to Dream3D’s official data, the Ultra SLM process achieves:

· Printing speed: ↑ 5–30× faster

· Manufacturing cost: ↓ over 30%

· Productivity per machine: ↑ 10× higher

· Support-free printing

· Exceptional cost-performance ratio

How Ultra SLM Achieves Ultra-High-Speed Printing

Unlike conventional SLM, Ultra SLM does not fully melt the metal powder. Instead, it employs polymer-coated metal powders, where a composite polymer binder coats each metal particle. During printing, only the binder melts — not the metal itself — enabling ultra-fast laser scanning close to the galvanometer’s maximum speed.

After printing, the parts undergo post-processing including machining, debinding, and sintering, resulting in fully dense metal components. The process effectively merges the front half of SLS (Selective Laser Sintering) with the latter stages of Binder Jetting (BJ) and Metal Injection Molding (MIM).

Step 1 — Powder Coating

Dream3D uses its proprietary polymer composite coating process to produce metal powders chemically similar to MIM feedstock but optimized for laser-based shaping.

Step 2 — Laser Printing

The coated metal powder is sintered using a laser, melting only the polymer binder. Because no full metal melting occurs, printing is up to 30× faster than standard SLM. Even complex, suspended geometries require no support structures or base plates — parts can be freely arranged within the powder bed for maximum packing density, and leftover powder is fully recyclable.

Dream3D recommends using SLS-type laser printers (from entry-level consumer models to million-yuan industrial systems) equipped with either fiber or CO₂ lasers. Minor hardware modifications further enhance performance.

Step 3 — Green Part Processing

After printing, the “green parts” are strong enough to handle automated powder removal via air or water jets — no wire-cutting or manual grinding needed. Because of their high mechanical strength, pre-sinter machining (turning, milling, drilling, or polishing) is possible, particularly beneficial for hard-to-machine metals, saving significant post-processing costs.

Step 4 — Catalytic Debinding

Printed parts can be processed together with MIM parts in standard catalytic debinding furnaces, removing most of the binder efficiently to form a “brown part” that retains its geometry.

For solvent-based debinding users, Dream3D recommends using Headmade Materials’ wax-based coated powders (see: Headmade Materials).

Step 5 — Thermal Sintering

Finally, the debound parts undergo pressureless sintering in standard MIM furnaces. During heating, residual binders decompose into gases and escape, allowing the metal particles to sinter and densify, reaching 97–99% density with dimensional tolerance of 0.3–0.5% — and uniform shrinkage across X, Y, and Z axes.

Applicable Equipment and Use Cases

Q: Which printers can use this process?
A: Most SLS-type polymer printers can directly print Dream3D’s catalytic-debinding metal powders or Headmade’s wax-based powders with minimal modification. Dream3D has validated full process parameters on EOS platforms, providing a universal “light modification kit” for improved print quality and efficiency.

Q: What types of metal parts are suitable?
A: Parts with moderate batch sizes, high geometric complexity, and materials including stainless steel, tool steel, titanium, copper, superalloys, refractory metals, and hard alloys. Ideal part dimensions range from 20–350 mm, wall thickness from 1–15 mm, and typical tolerances of ±0.3 mm (up to ±0.1 mm under optimized conditions).

About Dream3D

Dream3D is a high-tech enterprise incubated by the Shenzhen Guangming District Government, Leaguer Innovation, Leaguer Angels, and the Tsinghua University Research Institute. The company focuses on developing revolutionary metal 3D printing technologies.

Its core team includes scientists from Harbin Institute of Technology, Helmholtz Association (Germany), University of Utah (USA), and University of Cambridge (UK).

Headquartered in Shenzhen’s CMG Smart Park and Zhejiang Tsinghua Research Institute, Dream3D operates a 2,000 m² facility housing the world’s first ultra-high-speed laser metal 3D printing system. The system’s single-laser scanning speed reaches 30 m/s — roughly 30× faster than conventional metal SLM systems — and is supported by state-of-the-art precision instruments and materials research capabilities.

Collaboration Opportunities

Dream3D welcomes partnerships with:

· End-users seeking high-performance, cost-effective 3D-printed metal parts.

· Manufacturers aiming to integrate next-generation ultra-high-speed laser metal printing lines.

· Material, equipment, and process developers eager to co-create and advance 3D printing technologies.

Interested partners can submit a collaboration form via QR code provided by Dream3D. The company pledges to respond within 48 hours.

Dream3D believes that every collaboration is a catalyst for shared value creation. Through the synergy of complementary strengths and precisely aligned business models, the company aims to achieve a “1 + 1 > 2” multiplier effect, realizing the vision of mutual success and sustainable innovation in the metal 3D printing industry.

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