In this study, geometric forms of maraging steel dies used in aluminum extrusion were optimized by means of flow dynamics as well as surface quality and mechanical properties of the final part. Maraging steel (MS1) dies were produced by Direct Metal Laser Sintering (DMLS), a Selective Laser Sintering (SLS) method, using EOS M290. Dies were not subjected to any conventional finishing post processes. Field tests were carried out in an industrial aluminum extrusion facility. Results presented that DMLS is a promising method for the production of dies with complex inner sections with high accuracy, high speed and low cost. Production of high quality extruded profiles was possible using additive manufactured dies directly from production without applying any finishing post process
