Engineers from RMIT University have developed an innovative 3D-printed titanium alloy that is about a third cheaper to produce than commonly used titanium alloys, marking a significant advancement for industries like aerospace and medical devices.
The research team replaced the increasingly expensive vanadium — a key component in traditional titanium alloys — with more readily available and lower-cost materials, generating an alloy that offers improved strength and uniformity in 3D printing.
The new alloy, developed at RMIT’s Centre for Additive Manufacturing (RCAM), avoids the problematic columnar microstructures that cause uneven mechanical properties in some 3D-printed metals.
This breakthrough allows the titanium to print more evenly, resulting in a stronger and more ductile final product.
Ryan Brooke, RCAM PhD candidate and lead author of the study, said testing demonstrated improved performance over the standard 3D-printed titanium alloy Ti-6Al-4V.
Brooke, who recently accepted a Research Translation Fellowship at RMIT to explore commercialisation pathways, stated: “3D printing allows faster, less wasteful and more tailorable production yet we’re still relying on legacy alloys like Ti-6Al-4V that doesn’t allow full capitalisation of this potential. It’s like we’ve created an aeroplane and are still just driving it around the streets.”
He added: “New types of titanium and other alloys will allow us to really push the boundaries of what’s possible with 3D printing and the framework for designing new alloys outlined in our study is a significant step in that direction.”
The alloy is approximately 29 per cent cheaper to produce than traditional titanium alloys, though the exact formulation was withheld for commercial reasons.
The team developed a cost- and time-efficient method for selecting alloying elements tailored to additive manufacturing processes, enabling enhanced predictability of grain structure in printed metals — a key factor for mechanical consistency.
Brooke further emphasised the practical impact of the innovation: “By developing a more cost-effective formula that avoids this columnar microstructure, we have solved two key challenges preventing widespread adoption of 3D printing.”
Reflecting on industry engagement through CSIRO’s ON Prime program, where he consulted aerospace, automotive, and MedTech professionals, Brooke noted: “What I heard loud and clear from end users was that to bring new alloys to market, the benefits have to not just be minor incremental steps but a full leap forward, and that’s what we have achieved here.”
He concluded: “We have been able to not only produce titanium alloys with a uniform grain structure, but with reduced costs, while also making it stronger and more ductile.”
Study corresponding author Professor Mark Easton highlighted the collaborative nature of next steps, stating: “We are very excited about the prospects of this new alloy, but it requires a team from across the supply chain to make it successful.
“So, we are looking for partners to provide guidance for the next stages of development.”
Samples of the new titanium alloy were produced and tested at RMIT’s Advanced Manufacturing Precinct in Melbourne.
The research findings were published in the journal Nature Communications under the title “Compositional criteria to predict columnar to equiaxed transitions in metal additive manufacturing”.
RMIT has also filed a provisional patent to protect this innovative alloy design framework while exploring commercialisation opportunities in the aerospace and medical device sectors.
This development signals a promising shift in titanium additive manufacturing, offering a leap forward in cost efficiency and material performance compatible with the full potential of 3D printing technology.
