How Much Dose Titanium 3D Printing Cost ?

3D Printing Titanium: Is the High Investment Cost Worth It?

Titanium is a highly valued engineering material widely used in high-performance manufacturing and medical applications due to its excellent biocompatibility and strength-to-weight ratio. Titanium parts can be three to four times stronger than stainless steel and also have a higher melting point.

Titanium’s mechanical strength and corrosion resistance have made it highly recognized in the aerospace industry. 3D-printed titanium components are now approved for use in commercial and military aircraft airframes, blades, housings, and other high-load components. However, the short-term cost of 3D-printing titanium is high regardless of the part size or quantity, leading many companies to outsource manufacturing or produce simpler parts that are not as effective as titanium alloys.

Long-Term Value of Titanium Alloys

In the long run, the value of investing in titanium 3D printing depends largely on the application field and industry.

The Necessity of Titanium Alloys

Titanium alloys are crucial when other engineering materials cannot meet the demands. Here are a few scenarios where titanium stands out:

• Biocompatible Metal Parts: 3D printing has revolutionized the medical implant market, and titanium alloys are widely used in spine, hip, and knee surgeries due to their excellent biocompatibility and mechanical properties. The porous structure of 3D-printed titanium can seamlessly integrate into bone tissue, allowing for customized implants tailored to patients’ needs.
• Lightweight, High-Strength Parts: Titanium’s high strength-to-weight ratio makes it ideal for the aerospace and automotive industries. Lightweight yet strong titanium parts can significantly improve performance, ensure safety, and enhance fuel economy.
• High-Temperature Applications: Titanium alloys are well-suited for high-temperature components due to their high absolute strength and density weight ratio. Titanium parts demonstrate excellent corrosion resistance at both high and low temperatures, maintaining stable performance in harsh environments.

Understanding Titanium Alloys

Titanium alloys are often mixed with other metals to achieve optimal mechanical properties. Here are some of the common titanium alloys:

• Ti-6Al-4V: This is a popular aerospace-grade titanium alloy that is 40% lighter than 17-4 PH stainless steel but has a higher strength-to-weight ratio. It is used in precision manufacturing, medical equipment, aerospace, automotive, and military applications.
• Other Titanium Alloys: Titanium Ti GR23 (Grade 23) and Cp-Ti (Grade 1) are specialized titanium alloys used in medical implants. Grade 23 is biocompatible, and Cp-Ti has a very high purity level.

More Resources:

Titanium – Source: Wikipedia

3D Printing Technologies for Titanium Alloys

Understanding different 3D printing technologies is crucial to identifying the best process and equipment for titanium printing.

1. Powder Bed Fusion (PBF)
   Selective Laser Melting (SLM), Direct Metal Laser Sintering (DMLS), and Electron Beam Melting (EBM) all fall under Powder Bed Fusion technologies. PBF printers distribute a fine layer of metal powder and selectively melt the cross-section of each layer using a laser or electron beam. These technologies offer very high resolution, ideal for complex, precision components.

However, the cost of PBF equipment is high, often requiring investments of over $1 million, including facility upgrades and post-processing equipment.

2. Binder Jetting
   Binder jetting printers, such as the Markforged PX100, use a binder to hold metal powder together, then sinter the loosely bound parts in a furnace to create the final product. This technology allows for the simultaneous printing of multiple components, which are sintered together, resulting in higher production efficiency. PX100 delivers industrial-grade performance and production efficiency at a lower entry cost than PBF.

3.Bound Powder Extrusion
This newer technology, employed by printers like the Markforged Metal X, involves embedding metal powder in a waxy polymer, which is then printed in layers like traditional FFF printing. The printed component is cleaned and sintered afterward to remove non-metallic elements and obtain the final metal product.

This method is ideal for businesses with limited budgets, costing less than $200,000. Unlike PBF and binder jetting, bound powder extrusion is safer because the metal powder is encased in the polymer and poses no hazard.Directed Energy Deposition (DED)
DED technologies deposit metal materials layer by layer from a nozzle. Common DED machines include Electron Beam Additive Manufacturing (EBAM) and Laser Material Deposition (LMD). They are suitable for manufacturing large structures without handling powder risks. However, the resolution is relatively low, and the cost is similar to PBF equipment.

“Titanium 3D printing not only has advantages in terms of process, but also in terms of cost. With the price reduction of fiber lasers and metal 3D printing powder, the cost of 3D printing titanium alloy has gradually decreased. The machining cost of the Apple Watch series 6 case is about US$18, while the cost of titanium alloy produced through 3D printing technology is about US$15, which already has a competitive advantage on the cost side.

In addition, the price of metal 3D printing powder in my country continues to decline. The average selling price of BLT’s self-made metal 3D printing powder dropped from US$200,000/ton in 2020 to US$108,500/ton in 2022, a decrease of 45.9%. According to the Qianzhan Industry Research Institute, the downward trend in laser prices in my country is obvious. The price of 3kW fiber lasers in my country has dropped from US$55,500/unit in 2018 to US$14,200/unit in 2021, a decrease of 75.0%. According to the China Economic Industry Information Research Network, the average price of laser galvanometers in my country has dropped from US$309/set in 2017 to 297 yuan/set in 2021.”