Researchers at Royal Melbourne Institute of Technology (RMIT) have successfully developed a new 3D-printed titanium alloy that costs approximately 29% less than conventional titanium alloys. By replacing expensive vanadium with a more economical material combination, this innovative technology offers a more cost-effective solution for the aerospace and medical device industries. The findings have been published in Nature Communications.

The study was led by RMIT's Centre for Additive Manufacturing (RCAM), with PhD candidate Ryan Brooke as lead author. Brooke stated: "Compared to the standard 3D-printable titanium alloy Ti-6Al-4V, our alloy shows improvements in both strength and performance." The team has filed a provisional patent for the technology and is exploring commercialization pathways. Brooke added: "3D printing enables rapid, low-waste customized production, but traditional alloys limit its potential. This new titanium alloy will help us push the boundaries of 3D printing."

The new alloy design framework developed by the team not only reduces production costs but also addresses the common issue of microstructural inhomogeneity in 3D-printed metals. By optimizing the material formulation, the new alloy avoids the columnar grain structures typically seen in conventional 3D-printed titanium alloys, thereby improving mechanical property uniformity. Brooke emphasized: "We didn't just lower the cost—we made the alloy stronger and more ductile."

Corresponding author Professor Mark Easton said the team is actively seeking industry partnerships to advance the technology: "Successful commercialization of this technology requires collaboration across the supply chain. We look forward to working with industry partners on the next phase of development." Alloy samples have already been produced and tested at RMIT's Advanced Manufacturing Precinct.