3D printing boost from cheap titanium powder
22 Jan 2014 by Evoluted New Media
The high cost of titanium powder has prohibited its use in 3D printing – with plastics being the preferred alternative – but Rotherham-based Metalysis have developed a new way to produce titanium powder at a low-cost.
The powder has been used in the Renishaw 3D printer at the University of Sheffield to produce titanium components for the automotive, aerospace and defence industries.
In a world-first, Metalysis have taken rutile sand – a naturally occurring titanium ore found in beach sands – and transformed it directly into titanium powder using electrolysis. This new method is cost-effective and less toxic than the currently used energy-intensive and toxic Kroll process. The resulting powder can be used in additive layer manufacturing, and a wide variety of new applications.
“Metalysis’ rutile-derived titanium powder is produced at lower cost and is suitable for 3D printing so that manufacturing metal components becomes more economical,” said Dion Vaughan, CEO of Metalysis.
Vaughan believes the process could reduce the price of titanium by as much as 75%, making it almost as cheap as speciality steels. It could even replace aluminium and steel in many products.
The powder has been used at the University of Sheffield to manufacture automotive parts – another world first.
“Most people associate 3D printing with plastic parts, but, with Metalysis’ titanium powder, we have for the first time demonstrated its potential in the manufacturing of metal parts,” said Professor Sir Keith Burnett, University of Sheffield Vice-Chancellor.
“This is potentially a significant breakthrough for the many sectors which can benefit from its low-cost production. We look forward to continue to work with Metalysis as they develop this ground-breaking technology.”
Professor Iain Todd, Director of the Mercury Centre, which houses the Renishaw Printer, said that there are significant challenges to overcome before metallic 3D printing is taken from the lab to production – not least in terms of material cost.
“The step-change in terms of process economics that this material breakthrough provides takes us even closer to the time when 3D printing of metals such as titanium is considered the norm rather than exceptional.”
