The direct laser sintering is a layered manufacturing process which can produce any desired threedimensional
parts with simple or complex shapes. Recent research in this area has focused on the
direct laser sintering of metal powder. Cu-based metal systems are preferable in direct laser
sintering because of its good thermal performance and high electrical conductivity. This paper
reports on the research work in direct laser sintering of a multi-phase Cu-based powder in details.
A composite metal powder mainly consisting of Cu, Cu3P was successfully sintered in a selfdeveloped
Rapid Prototyping machine in ambient atmosphere at room temperature. 68.9%
theoretical density and average surface roughness Ra 14-16mm were achieved with negligible
distortion and shrinkage. Some complex 3-D parts have been fabricated successfully. Furthermore,
the influence of the amount of binder on density and tensile strength were also investigated.