Soon it will be possible to take 3D prints of automotive parts using titanium powder.
So far, 3D printing was limited to plastic, but now Metalysis - a Rotherham, England, based company - has developed a new way of producing low cost titanium powder that will aid this process.
The use of titanium powder to manufacture automotive parts will be the first effort in the world. Metalysis has apparently created titanium powder from rutile sand, which is a natural ore that is found in beach sands.
"We are delighted that this innovative work is being undertaken in the University of Sheffield's world-leading Faculty of Engineering," said Professor Sir Keith Burnett, Vice Chancellor of University of Sheffield. "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. This is potentially a significant breakthrough for the many sectors which can benefit from its low-cost production. We look forward to continuing working with Metalysis as they develop this ground-breaking technology."
Until now, 3D printing with metal has been extremely expensive especially because of the cost of titanium powder, which sells for $200 to $400 per kg. However, with the new, low-cost titanium powder, the use of titanium in machinery across industries like automotive, aerospace and defence would increase greatly.
The parts were made by the Renishaw 3D printer at the Mercury Centre (within the Department of Materials at the University of Sheffield). The machinery gave a glimpse into how feasible it is to produce titanium components using the additive layer manufacturing process.
"There are significant challenges to overcome in taking emerging technologies like metallic 3D printing from the lab to production, not least of which is material cost. The step-change in terms of process economics that this material breakthrough provides takes us ever closer to the time when 3D Printing of metals such as titanium is considered the norm rather than exceptional," said Iain Todd, Director of the Mercury Centre.
The Metalysis process is both cheaper and environmentally friendly when compared to existing methods like Kroll process, which is used for titanium production. The Kroll process is labor intensive and time consuming, as well as costly. On the other hand, Metalysis is faster and less expensive as it takes rutile and turns it into powdered titanium via electrolysis.
Moreover, another benefit of 3D printing is that waste is reduced, which again decreases cost.
If the inexpensive process of extracting titanium powder from rutile sand is used, then the cost of production goes down greatly which in turn allows for the metal's widespread use.
"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. "The Metalysis process could reduce the price of titanium by as much as 75 per cent, making titanium almost as cheap as specialty steels. We believe that titanium made by the Metalysis process could replace the current use of aluminium and steel in many products. This world-first for a titanium 3D printed component brings us a step closer to making this a reality."
Along with titanium powder, Metalysis is also developing tanalum powder. The company will use its technology to manufacture a wide variety of specialist metals.
