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Howard
@Lukas
How solid (in terms of the percentage) are the parts that your DMLS machine produces?
My only worry (great thread btw, I love nerdy DIY stuff like this), despite all the FEA and safety factors you've shown us, is that because laser sintered metal is never going to be 100% solid as a material, this, combined with the extent of your weight reduction, could make the end result a bit more brittle and fragile than you might be expecting.