Direct laser metal sintering (DMLS) has been used by many manufacturers since the late s to make complex metal parts that can’t easily be produced with the likes of stamping or extrusion. This 3D printing process is complex in and of itself, but it’s also a unique technology that’s hard to find an alternative for when it comes to specific components. Whether you’re considering having your own products printed through DMLS, or simply just intrigued by the concept, read on to find out all about this manufacturing method.
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DMLS is a form of 3D printing, and it uses powder-bed fusion technology to work. It shoots a high-powered fiber laser beam at a single layer of metal powder, which then fuses together onto the previous thin layers. It continues this process until the metal part is fully printed.
You might be wondering where the “sintering” part comes in, as it doesn’t seem to occur. This is actually a misnomer that happened after the translation of DMLS. In Germany (where this tech was created), it was called Direktes Metall-Laser-Schmelzen, schmelzen meaning “to melt.” When translated into English, the “S” became sintering, but because of this slight confusion, you’ll sometimes find this process called direct metal laser melting.
Now that you get the gist, we’re going to get more into the nitty gritty of the DMLS process. The start of the process involves the fiber laser beam, which can have up to 1,000 W of power. It begins scanning the cross-section of a part layer and starts melting the powder particles together.
While there is often one laser beam, some machines have the capacity to shoot out four beams at a time, which quadruples how quickly the process moves along. Usually, a DMLS printer will scan and laser at a speed of around 7 m/s.
Once the first layer is finished, the bed moves down, and another layer of metal powder is put down. Then, the system will fill the printing chamber with an inert gas to prevent the part from oxidizing during the rest of the printing process. After this takes place, the melting of the next layer occurs until the part is complete.
The quality and accuracy of the print comes down to how good the laser and optical components of the printer are. Normally the focal point is between 40 to 100 microns in diameter—which means the smallest feature you can get is 40 microns.
In the picture below, you can get a good idea of how a DMLS printer looks and what components are featured.
Interviewers ask this question to see how you manage your workload under pressure and ensure critical deadlines are met. You need to explain how you assess tasks by urgency and impact, communicate proactively with your team, and stay flexible to adjust priorities when unexpected issues arise.
Example: When juggling multiple deadlines, I start by identifying which tasks have the most immediate impact on the project’s progress. I keep open lines of communication with my team to adjust priorities as needed and ensure everyone’s aligned. For example, if a last-minute change arises, I reassess my schedule and shift focus accordingly to keep everything on track without compromising quality.
Interviewers ask this to see if you can effectively communicate and collaborate, ensuring smooth project progress and avoiding conflicts. You need to explain how you coordinate drawings and schedules with other teams to prevent clashes and ensure accuracy.
Example: In my experience as a structural steel detailer, I regularly collaborate with architects, engineers, and contractors to ensure designs align. For example, I’ve coordinated with MEP teams to avoid clashes and with site managers to adjust details on the fly. This teamwork helps keep projects on schedule and reduces costly revisions, ultimately delivering a smoother construction process.
Hiring managers ask this question to understand your experience scope and how well you fit their project needs. You need to clearly describe the types of projects you worked on, your specific tasks, and the range of materials or structures involved.
Example: I’ve worked on a range of projects from commercial buildings to bridges, each with its own challenges. My role usually involves creating detailed steelwork drawings and coordinating with engineers to ensure accuracy. For example, on a recent office complex, I handled complex steel connections and varied materials like galvanized and stainless steel, which required close attention to detail and collaboration across teams.
This question checks if you prioritize accuracy and compliance to safety and quality standards. You need to explain that you carefully review all applicable codes, use reliable reference materials, and double-check your work to ensure it meets those standards.
Example: When working on a project, I start by thoroughly reviewing the latest British Standards and client specifications to guide my detailing. I cross-check dimensions and connections to ensure compliance, often consulting with engineers if anything seems unclear. For example, on a recent job, adhering closely to BS EN was key to ensuring fabricator acceptance and site safety. Clear communication and attention to detail help me deliver reliable, code-compliant drawings every time.
Employers ask this question to see if you can improve your work process and increase efficiency by leveraging software tools. You need to explain how you noticed repetitive tasks that could be automated, what specific changes you made to the software, and how these changes improved your workflow or accuracy.
Example: In a previous role, I noticed our detailing software lacked certain shortcuts that slowed down the process. I worked with the IT team to create custom scripts that automated repetitive tasks, like material tagging. This small change reduced errors and saved time, allowing us to focus more on complex designs. It made a noticeable difference in both speed and accuracy on tight project deadlines.
Questions like this help interviewers see how you organize complex projects and ensure accuracy. You need to explain that you review design specifications, create precise 3D models, generate detailed drawings including dimensions and welding info, and double-check all details for errors before fabrication.
Example: When creating steel fabrication drawings, I start by reviewing the architectural and structural plans to fully understand the design intent. Then, I model the steel components in 3D software to verify fit and connections. After that, I generate detailed drawings showing dimensions, welds, and bolt locations. I always coordinate closely with engineers and fabricators to ensure accuracy and practical buildability. This helps avoid issues during fabrication and installation.
Interviewers ask this question to see if you understand how to create safe, accurate, and practical connections in steel structures. You need to explain how you identify critical load paths to ensure strength, describe your process for checking details against standards, and give an example of collaborating with fabricators or engineers to adjust designs as needed.
Example: When detailing connections in structural steel, it’s important to understand how the loads transfer through each joint to maintain overall stability. Precision in drawings helps avoid fabrication errors, saving time on site. I also find keeping close communication with engineers and fabricators crucial—sometimes a quick chat can clarify design challenges before they become bigger problems. For example, adjusting bolt sizes early on can prevent costly rework later.
What they want to understand is how skilled you are with relevant 3D modeling tools and how you use them to handle real-world detailing problems. You need to clearly state your experience with software like Tekla Structures and briefly describe how you’ve used it to coordinate models and resolve complex design issues.
Example: I’ve worked extensively with Tekla Structures and AutoCAD to create detailed 3D models for various steel projects. Using these tools, I’ve tackled complex connections and ensured accurate fabrication details. Collaborating closely with engineers and fabricators, I often use 3D models to clarify design intent and resolve issues early, which helps keep projects on track and reduces errors during construction.
This question helps interviewers see how you stay connected to the bigger picture and work effectively with others to meet project goals. In your answer, explain that you maintain regular communication with the team, incorporate feedback quickly, and use tools like checklists to verify your drawings meet all requirements.
Example: I make it a point to stay in regular contact with the design team and site engineers, so I fully understand their expectations and can adapt quickly. When I receive feedback, I review and incorporate it to keep my drawings aligned with the project’s needs. I also cross-check all details against the specifications to ensure accuracy, which helps avoid delays and keeps everything moving smoothly.
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Included in AI interview practice Improve your answer 3 Improvements Found. View here How do you approach troubleshooting errors in your detailing work?What they’re looking for is how you systematically find and fix mistakes to ensure accuracy and maintain project quality. You need to say that you first review drawings carefully to identify the cause, then correct the details precisely, and finally communicate the changes clearly to your team or supervisors.
Example: When I spot a mistake in my detailing, I first dig into what caused it, whether it’s a measurement slip or a misread drawing. Then, I work out the best fix, making sure it fits with the project specs. I find it’s important to keep everyone in the loop and record what was changed, so the team stays aligned and similar issues can be avoided down the line.
This interview question assesses your ability to adapt and maintain accuracy when project requirements evolve. You need to explain that you carefully review changes, communicate with the team, and update your drawings to ensure everything aligns with the new scope.
Example: When project scopes or designs shift, I stay flexible and communicate quickly with the team to understand the changes. For example, on a recent bridge project, a last-minute design update required revising several steel connections. By working closely with engineers and updating the details promptly, we avoided delays and kept the build on track. Staying organized and open to collaboration is key to adapting smoothly.
Interviewers ask about load paths to see if you understand how forces move safely through a structure and impact your detailing decisions. You need to explain that load paths guide forces from beams to columns to foundations, influence your choice of welds or bolts, and help prevent structural failures by ensuring stability.
Example: Load paths are fundamental in guiding forces safely through a structure, ensuring each connection carries its share without overload. When detailing, understanding these paths helps pinpoint where stronger joints or reinforcements are needed, like at beam-to-column connections. This careful planning not only supports stability but also prevents failures, keeping the whole framework reliable under different loads.
Employers ask this question to see how well you communicate and work with others under pressure. You need to explain a specific situation where you listened to different viewpoints, identified the main issue causing the conflict, and helped your team reach a solution together.
Example: In a previous project, two team members disagreed on design details, which slowed progress. I listened to both sides, clarified misunderstandings, and encouraged a joint review of the drawings. By fostering open dialogue and focusing on the shared goal, we reached a solution everyone supported. This not only resolved the issue but strengthened the team’s communication moving forward.
Interviewers ask this question to see how well you can interpret and manage difficult structures accurately using both your skills and available tools. You need to explain how you carefully review 3D models or CAD drawings, use specialized software features like clash detection, and apply problem-solving strategies to ensure accuracy and resolve conflicts in complex geometries.
Example: When working with complex geometries, I start by carefully reviewing the drawings and 3D models to fully understand the design intent. I rely on software like Tekla or AutoCAD to create precise details, ensuring everything fits together correctly. If something seems off, I double-check and collaborate with engineers to resolve issues early. This approach helps me maintain accuracy and avoid costly mistakes during fabrication.
Questions like this assess your time management and problem-solving skills under pressure. You need to briefly describe the project, explain how you organized your tasks, and highlight the outcome to show you can meet tight deadlines effectively.
Example: Sure! Here’s a natural, concise response you might use:
On one project, we faced a sudden change in design that compressed our timeline significantly. By prioritising clear communication and focusing on key details, I coordinated closely with engineers and fabricators to keep progress on track. Despite the pressure, we completed all steel detailing accurately and on schedule, which helped avoid costly delays on site. It was a great example of teamwork under time constraints.
Interviewers ask this question to see if you can clearly share and receive important project information, which helps prevent errors and keeps the team on track. You need to say that you actively listen to understand requirements, use timely communication tools to keep everyone updated, and adjust your communication style to suit different team members.
Example: I make sure to really listen when project managers explain the requirements, so I fully understand what’s needed. I keep communication clear and prompt, whether it’s through emails or quick chats, to avoid any delays. I also adjust how I share information depending on who I’m talking to—sometimes more technical with engineers, or straightforward with clients—to keep everyone on the same page and encourage smooth teamwork.
What they want to know is how you handle pressure and solve problems in your work. You need to describe a specific difficult project, explain the challenges clearly, and show the steps you took to overcome them successfully.
Example: One time, I worked on a complex steel frame with tight tolerances and overlapping deadlines. Coordinating closely with engineers and fabricators, I double-checked details and adjusted drawings promptly to prevent clashes. Clear communication and staying organised helped us meet quality standards without delays, turning a potentially tricky project into a smooth delivery.
This interview question assesses your ability to spot and address risks early to prevent costly errors in the construction process. You need to briefly explain when you noticed a discrepancy, how you confirmed it by consulting others, and what steps you took to resolve it before it caused delays.
Example: In a previous project, I spotted a discrepancy between the steel beam dimensions on the drawings and the on-site measurements. I double-checked the specs and raised it with the engineer before fabrication began. This early flag helped us avoid costly rework, keeping the schedule intact and ensuring the structure fit perfectly when assembled. Catching these things early really saves time and resources down the line.
Hiring managers ask this question to see if you can accept and use feedback to improve your work and collaborate effectively. You need to say that you listen carefully to feedback, reflect on it to make necessary improvements, and appreciate it as an opportunity to grow.
Example: I see feedback as an important part of improving my work. When a supervisor or colleague points out something, I listen carefully and try to understand their perspective. For example, in a previous project, a teammate suggested a different approach to a connection detail that saved time and materials. Being open to that insight helped me grow, and I always aim to use feedback constructively to deliver better results.
Questions like this assess your understanding of precision and efficiency in your work. You need to explain that you use software to create detailed, accurate models and regularly cross-check dimensions and connections to prevent errors.
Example: I rely on software to create precise 3D models, which helps me catch potential issues early. For example, using tools like Tekla Structures allows me to verify connections and dimensions before production. This reduces errors and streamlines communication with fabricators. Regularly reviewing models against project specifications ensures everything fits as intended, saving time and avoiding costly mistakes on site.
Interviewers ask this to gauge your attention to detail and commitment to quality, which are crucial in structural steel detailing. You need to explain that you carefully review project specifications, use precise measurement tools, and double-check your drawings to ensure accuracy and prevent costly errors.
Example: To ensure accuracy in my detailing, I double-check all dimensions against the design drawings and use software tools carefully to avoid errors. I also cross-reference with project specifications and communicate with engineers if something isn’t clear. For example, on a previous project, catching a small discrepancy early saved time during fabrication, preventing costly revisions down the line. Care and clear communication really make the difference.
What they want to know is if you actively keep your skills current to improve your work quality and efficiency. You should say that you regularly attend industry webinars and workshops to learn about new software, and apply these updates to make your detailing more accurate and efficient.
Example: I make it a habit to regularly explore new features in the software I use, often through online tutorials and user forums. When I learn something helpful, I apply it directly to my projects, which improves efficiency and accuracy. Staying open to trying updated tools or plugins has helped me adapt quickly, ensuring my work remains current and meets industry standards. For example, recently adopting 3D modeling enhancements sped up my detailing process significantly.
Questions like this assess your problem-solving skills and ability to innovate under pressure. You need to clearly describe the challenge you faced, explain the creative solution you applied, and share the positive results that came from your approach.
Example: In a recent project, we faced tight space constraints that made standard steel connections impractical. To solve this, I designed a bespoke joint using thinner plates and custom bolt patterns, ensuring structural integrity without compromising space. This approach not only met safety standards but also sped up installation, saving time and reducing costs for the client. It was rewarding to see a practical, tailored solution make a real difference on site.
Employers ask this question to see if you can work well with others and contribute to a team’s success. You need to describe a specific project where you communicated effectively and coordinated tasks with coworkers to meet deadlines and ensure accuracy.
Example: In a recent project, I worked closely with engineers and fabricators to resolve a complex steel connection issue. By sharing detailed drawings and discussing potential challenges early on, we avoided delays and rework. This teamwork ensured the structure met all safety standards and was completed on schedule, highlighting how open communication and collaboration can really make a difference in delivering quality results.
Interviewers ask this to assess your technical skills and experience with essential industry software. You need to clearly state the software you know, like AutoCAD, describe how you've used it for accurate steel detailing drawings, and show your ability to quickly learn new tools or updates.
Example: I’m proficient in software like Tekla Structures and AutoCAD, which I use regularly to create precise, detailed steelwork drawings. I’ve worked on projects where accurate modelling was crucial to avoid clashes on-site, so I focus on both detail accuracy and practicality. I’m also quick to learn new software updates or tools as needed, ensuring my workflow stays efficient and up to date with industry standards.
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