3D Printing Titanium Services
3D printing solutions provided by Wstitanium include: DMLS, DMLM, SLM, LMF, LPBM. Manufacture fully functional titanium prototypes and custom titanium parts in 7 days or less for final parts for end-use applications.
- Production-Grade Material Prototyping
- Arbitrary Complex Geometries
- Tight Tolerances +/- 0.002”
- Reduce Steps In Assembly
- Functional End-Use Parts
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3D Printing Services for Titanium Parts
Titanium is a difficult metal to machine, especially when it comes to CNC machining. For one thing, titanium has a low thermal conductivity. This means that when a CNC machine, for example, performs milling, the heat generated is stored in the tool. This can cause the tool to wear quickly. In addition, since machining involves cutting and removing material, the process can result in a lot of material waste. As a result, many companies are looking for better alternative solutions to manufacture titanium parts. Metal 3D printing of titanium is proving to be a viable alternative. The most commonly used titanium grade is the alloy Ti6Al4V (Ti64). In addition to Ti64, pure titanium can also be used for 3D printing.
Wstitanium 3D Printing Workshop
Advantages of 3D Printing Titanium
3D printed titanium can be manufactured economically in small and medium batches. It is a more cost-effective option compared to methods such as CNC milling, turning or casting, as the cost does not depend on the complexity of the part. All that is needed to successfully manufacture titanium products is a 3D printer and metal powder, rather than relying on expensive tools or complex specialized solutions.
Reduced Waste of Material
Compared to traditional subtractive manufacturing processes, such as CNC machining, 3D printing is an additive manufacturing technology that does not generate a lot of material waste. During the manufacturing process, the remaining titanium powder can be used for the next print. In addition, 3D printing titanium can produce parts very close to the final desired shape, reducing the need for extensive post-processing and further reducing waste.
Design Optimization
3D printing is able to create parts with complex, lightweight structures that are difficult or impossible to manufacture with traditional methods. This means using less material while maintaining strength and functionality. One of the ways engineers achieve design optimization is through topology optimization in CAD software, which consolidates multiple parts into a single printed part, which can reduce assembly time, labor costs and potential failure points.
No Tooling or Setup Costs
For either casting or CNC machining titanium parts, custom tooling such as molds, fixtures, etc. is required. 3D printing eliminates the need for additional tooling because the parts are printed directly from the digital file. Changes to part design can be implemented quickly without the need for new tooling, reducing the costs associated with design modifications.
Shorter Leading Time
Wstitanium uses an in-house metal 3D printer, and the delivery of a single part may take only 1 day, while CNC machining and casting may take longer (as mentioned above, they require the help of tools or fixtures). 3D printing services have shorter manufacturing times and you can order parts on demand without the need for inventory reserves. This greatly reduces the risk of capital.
Customization and flexibility
3D printing allows custom parts to be made without reassembly, making it easier and more cost-effective to produce small batches or customized products, further reducing operating costs. For example, patient-specific surgical tools.
Energy efficiency
3D printing titanium services, such as electron beam melting (EBM) or selective laser melting (SLM), are more energy-efficient than CNC machining, especially when considering the reduced need for post-processing and material recycling.
Wstitanium In-house 3D Printing Technology
Since 2019, Wstitanium has spent more than $2 million to invest in metal 3D printing technologies, such as DMLM, DMLS, LPBF, and LMF. Among them, laser powder bed fusion (LPBF) is the most common.
DMLS
Direct Metal Laser Sintering (DMLS) is similar to Laser Sintering Technology (SLS), but instead of using polyamide, fine titanium powder is used to build the model layer by layer. A thin bed of titanium powder is laid down in the 3D printer. This layer is then sintered and solidified by a very powerful laser and will become the bottom layer of the part. The laser beam moves over a box filled with powder. After each layer, a new layer of powder is applied. The process is then repeated. Remove your part from the 3D printer and clean off any loose, unsintered powder. In most cases, there will be 3D printing support structures made of titanium on and around your part. These supports must be removed manually using very powerful circular saws and other tools. Once the supports are removed, manual polishing is required to remove traces of the supports. Post-finishing steps may then be required, such as polishing the entire part.
- Maximum titanium part size: 250 x 250 x 320 mm
- Minimum titanium part size: 5 mm x 5 mm x 5 mm
- Default Layer Height: 0.04 mm
- Optional Layer Heights: 0.05mm
- MOQ=1
- Tolerance：±0.02mm
- Surface Roughness: 150-400 Ra
- Cost: Depends Mainly on Weight
Titanium Alloy Grades for 3D Printing
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Titanium Alloy Grades for 3D Printing
The most commonly used titanium grade for 3D printing is the alloy Ti6Al4V (Ti64). In addition to Ti64, pure titanium can also be used for 3D printing. As 3D printing technology develops, material manufacturers create a variety of titanium powders suitable for 3D printing. These metal powders are carefully designed with uniform particle size and shape, which improves fluidity and packing density on the print bed. This enhancement enables smoother and more detailed printing and enhances mechanical properties by reducing inclusions and porosity. Most titanium 3D printing uses titanium alloys (metal materials containing alloys of titanium with other elements) rather than pure titanium. The type of titanium alloy used depends on the specific 3D printing application. Some common varieties are shown in the table below.
Alloy | Grade | Description | Applications |
Ti-6Al-4V | 5 | The most common and important titanium alloy for 3D printing, with excellent strength-to-weight, corrosion resistance, and biocompatibility | Aerospace components, automotive components, surgical instruments, medical implants |
Ti-6Al-4V-ELI | 23 | This purer titanium alloy has an “extra-low interstitial,” making it slightly weaker than Grade 5 but better for biomedical applications | Surgical instruments, medical implants |
Ti-6Al-2Sn-4Zr-2Mo |
| A near-alpha titanium alloy with high strength and excellent corrosion resistance | Aerospace components, aviation components, marine components |
Ti-5Al-5V-5Mo-3Cr |
| A beta titanium alloy with high strength and toughness that shows promise in 3D printing due to its poor machinability | Industrial components |
Titanium grade 5 6Al-4V is the most commonly used titanium alloy in additive manufacturing and is ideal for prototypes and functional parts in the aerospace, automotive and military sectors. It is also an excellent material for manufacturing parts with complex geometries and precision, as well as production tools. Titanium grade 23 6Al-4V is a biocompatible alloy that is often used in medical implants and prosthetics. Beta 21S grade titanium has higher strength than traditional titanium alloys such as Ti-6Al-4V, and also has better oxidation and creep resistance than traditional titanium alloys such as Ti-15V-3Cr. Of all titanium alloys, 21 grade titanium has the lowest hydrogen absorption efficiency. It is ideal for orthopedic implants and aerospace engine applications. Beta titanium is widely used in dental corrections. Cp-Ti (pure titanium) grades 1 and 2 are widely used in the medical field due to their biocompatibility with the human body. TA15 is a near-alpha titanium alloy with aluminum and zirconium additives. Parts made from TA15 have high specific strength, high load-bearing capacity and temperature resistance, so they can be used for heavy parts in aircraft and engine manufacturing.
Surface Treatment of 3D Printed Titanium Parts
Wstitanium offers titanium components with specialized surface finishes. Options such as strength, rust resistance, and metal conductivity can be added to titanium parts during post-processing. Surface treatments provided by Wstitanium’s titanium 3D printing services include shot peening, electrochemical polishing and CNC machining, heat treatment, and more.
Sandblasting
Sandblasting can remove defects, pits, rust and other contaminants from the surface of parts. Sandblasting is often used to prepare parts for coating. Different sandblasting methods include micro-sandblasting, brush blasting, bead blasting, etc. Sandblasting uses abrasives such as steel grit, silicon carbide, pumice, etc.
Shot Peening
Shot Peening can enhance the strength of a part and reduce its stress distribution. During the shot peening process, the part is subjected to multiple shots, which leave deformations on the surface of the part. The process adds a compressive stress layer.
Optical Polishing
Optical polishing is cost-effective and provides a bright surface effect. Optical polishing creates a micro-finish or super-finish on the surface of the part in preparation for further processing. Optical polishing processes are best suited for projects with low-volume, non-tolerance dependent geometries.
Electrochemical Polishing
Electrochemical polishing produces a mirror-like finish on metal parts and can also be used to prepare a part for further finishing. In this process, the part is placed in an electrolytic solution with a copper or lead cathode. An electric current flows through the solution, smoothing the surface of the part.
Electroplating
Electroplating adds a metal layer to the outside of a part, increasing its strength and durability. Electroplating dissolves the metal in an electrolytic solution and transfers it to the surface of the part. Some of the most common metals used in the electroplating process are copper and zinc.
CNC Finishing/Machining
CNC machining adds wear resistance, metal conductivity, strength, rust resistance, and more. CNC finishing can improve the appearance of the part and prepare it for final coating. Finishing may involve powder coating, sandblasting, passivation, and anodizing.
Heat Treatment
Heat treatment improves titanium’s mechanical properties, such as strength and toughness. This is a critical step for parts that are subject to high stresses.
| Titanium TiAl4V Heat Treated | Value |
|---|---|
| Yield Strength Rp 0.2% | 950-1050 MPa |
| Ultimate Tensile Strength Rm | 1000-1150 MPa |
| Elongation at Break | 9-15% |
| Young’s Modulus | 105-125 GPa |
| Relative Density | 99.5% |
Hot Isostatic Pressing (HIP)
HIP eliminates internal porosity in titanium parts, making them denser and stronger. During this process, the titanium alloy is heated to 1000⁰C for 60 minutes in an argon atmosphere and then slowly cooled.
| Titanium TiAl4V HIP | Value |
|---|---|
| Yield Strength Rp 0.2 % | 870-950 MPa |
| Ultimate Tensile Strength Rm | 950-1050 MPa |
| Elongation at Break | 13-16 % |
| Young’s Modulus | 105-125 GPA |
| Relative Density | 99.5% |
3D Printing Titanium Parts Application
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3D Printing Titanium Parts Design Optimization
Titanium is by far the strongest 3D printing material from Wstitanium. You’ll notice this too when you design 3D models for this material. To get the better titanium 3D prints you’re looking for, here are some simple tips you should keep in mind: