NANOTUN3D · Project

3D-Printed Titanium Parts That Cut Material Waste by Up to Half

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Imagine making an airplane part from a block of titanium — you'd machine away most of that expensive metal just to get the shape you need. This project created a special titanium powder mixed with tiny nanoparticles so it can be 3D-printed into near-final shapes instead. The team achieved expected savings of 40% to 50% on raw material for critical parts in aerospace and mobility. They also tackled the safety, handling, and certification steps needed to move these printed parts from the lab toward real-world use.

By the numbers

40-50%

Expected material savings in critical applications

3-5 kg

Composite powder batches produced in laboratory atomizer

Consortium partners across 5 countries

56%

Industry ratio in consortium

SMEs in consortium

The business problem

What needed solving

Aerospace and mobility manufacturers waste enormous amounts of expensive titanium when machining structural parts from solid blocks — buy-to-fly ratios are notoriously poor. Traditional manufacturing also means long lead times, expensive tooling, and limited design freedom for complex geometries. Companies need a way to produce high-performance titanium parts with dramatically less waste and faster turnaround.

The solution

What was built

The project built a complete workflow for a nanomodified titanium alloy designed for 3D printing: from core-shell nanoparticle treatment of Ti powder, through lab-scale atomization producing reproducible 3-5 kg powder batches, to post-processing and certification protocols. They also delivered a Health, Safety and Environmental management system for handling nano-enhanced metal powders, with 11 deliverables in total.

Audience

Who needs this

Aerospace component manufacturers machining titanium parts with high waste ratesSpace hardware companies needing lightweight structural parts with long lead timesElectric vehicle and motorsport firms looking for lighter titanium componentsMetal powder producers wanting to expand into nanomodified AM materialsAdditive manufacturing service bureaus specializing in titanium parts

Business applications

Who can put this to work

Aerospace manufacturing

enterprise

Target: Tier 1-2 aerospace component suppliers

If you are an aerospace parts manufacturer dealing with expensive titanium waste from traditional machining — this project developed a nanomodified titanium powder and complete additive manufacturing workflow that achieves expected savings of 40% to 50% of material in critical applications. The core-shell nanoparticle treatment produces powder ready for standard AM machines, meaning you could integrate it without replacing your existing 3D printing equipment.

Space and satellite equipment

mid-size

Target: Space hardware and satellite component manufacturers

If you are a space equipment maker struggling with long lead times and high buy-to-fly ratios on titanium structural parts — this project built a workflow from powder production through post-processing and certification protocols specifically for AM. Lab-scale batches of 3-5 kg of composite powder were demonstrated, with reproducibility of the production process validated. The tool-less production approach cuts throughput times significantly.

Automotive and mobility

SME

Target: Lightweight component producers for electric vehicles and motorsport

If you are a mobility parts supplier looking to reduce weight and material cost on structural titanium components — this project developed a Ti-based alloy with nano-additives designed specifically for additive manufacturing processability. The consortium of 9 partners across 5 countries included 5 SMEs, meaning the technology was built with smaller manufacturers in mind, not just large OEMs.

Frequently asked

Quick answers

What kind of material savings can we actually expect?

The project objective states expected savings between 40% and 50% of material in critical applications. This comes from switching to additive manufacturing which builds parts layer by layer rather than machining from solid blocks, resulting in much higher buy-to-fly ratios.

Can this scale beyond laboratory batches?

The demonstrated deliverable produced powder batches of 3-5 kg in a laboratory atomizer, validating reproducibility of the powder production process. Scaling to industrial volumes would require larger atomization equipment, but the process parameters and powder characteristics have been established at lab scale.

What is the intellectual property situation and how can we license this?

The project was funded as an RIA (Research and Innovation Action) under Horizon 2020, with a consortium of 9 partners across 5 countries. IP ownership typically follows consortium agreement rules. Contact the coordinator AIDIMME in Spain to discuss licensing or collaboration opportunities.

Is this powder compatible with our existing AM machines?

The objective specifically states the powder was designed to be processed in well-known AM technologies. The core-shell nanoparticle treatment produces Ti64-like powder ready to be AM processed, suggesting compatibility with standard titanium AM equipment.

What about safety and certification for aerospace use?

The project developed a complete Health, Safety and Environmental management system plus all protocols to start qualification and certification of both material and process. This is critical groundwork, though full aerospace certification would still require additional steps with relevant authorities.

How long has this technology been in development?

The project ran from October 2015 to September 2019, a four-year development cycle. The consortium delivered 11 deliverables covering the complete workflow from powder production through post-processing and certification readiness.

Consortium

Who built it

The NANOTUN3D consortium of 9 partners across 5 countries (Belgium, Germany, Spain, Italy, UK) is strongly industry-oriented with a 56% industry ratio and 5 SMEs involved. This is a good sign for business relevance — the technology was developed with manufacturers at the table, not just academics. The coordinator AIDIMME is a Spanish technology institute classified as an SME, supported by 1 university and 3 research organizations providing the scientific backbone. The mix suggests the results are closer to industrial reality than a purely academic project would deliver.

INSTITUTO TECNOLOGICO METALMECANICO, MUEBLE, MADERA, EMBALAJE Y AFINES-AIDIMMECoordinator · ES
VLAAMSE INSTELLING VOOR TECHNOLOGISCH ONDERZOEK N.V.participant · BE
ZOZ GMBHparticipant · DE
LAURENTIA TECHNOLOGIES SLLparticipant · ES
UNIVERSITAT POLITECNICA DE VALENCIAparticipant · ES
ASOCIACION CENTRO TECNOLOGICO CEITparticipant · ES
TWI LIMITEDparticipant · UK

How to reach the team

AIDIMME (Instituto Tecnológico Metalmecánico) in Spain — a technology institute focused on metalworking, furniture, wood, and packaging industries. As an SME coordinator, they are likely open to industry partnerships.

Order a report on this consortium See INSTITUTO TECNOLOGICO METALMECANICO, MUEBLE, MADERA, EMBALAJE Y AFINES-AIDIMME profile →

Next steps

Talk to the team behind this work.

Want an introduction to the NANOTUN3D team to discuss licensing their nanomodified titanium powder technology or AM workflow? SciTransfer can arrange a direct meeting with the right technical contact.

Order a report on this topic More in Manufacturing & Industry 4.0