How does SLM compare to traditional manufacturing methods for titanium alloys?

Design Flexibility and Geometric Complexity

SLM provides far greater design freedom than traditional machining or casting methods. It enables lattice structures, internal channels and near-net shapes that are difficult to achieve through conventional titanium processing. Alloys such as Ti-6Al-4V can be built layer by layer with optimized topology for strength and weight reduction, offering significant advantages for aerospace, energy and medical applications.

Material Efficiency and Waste Reduction

Traditional machining removes large amounts of material from billets or cast parts, leading to high waste. In contrast, SLM uses only the required powder per part, minimizing scrap rates. This makes it highly efficient for producing titanium components that would be too costly to machine or cast with complex design requirements.

Mechanical Properties and Performance

SLM can achieve high tensile strength and stiffness due to rapid solidification, but may require HIP or heat treatment to match the fatigue resistance and density of forged or investment cast parts. For critical load-bearing components, hybrid manufacturing—combining SLM preforms with precision forging or CNC finishing—is often employed to meet aerospace requirements.

Lead Times and Rapid Prototyping

SLM eliminates the need for tooling and significantly reduces development cycles. Prototypes can be quickly produced from CAD data, allowing engineering validation before mass production. This is especially valuable in sectors such as aerospace and aviation or pharmaceutical and food, where customization and iteration are critical for functionality and regulatory compliance.