How does LENS 3D printing with Ti-6Al-4V compare to traditional manufacturing methods?

Material Efficiency and Cost Reduction

Traditional machining of Ti-6Al-4V involves high material wastage, especially when producing complex geometries from solid billet stock. LENS 3D printing deposits material only where needed, significantly reducing buy-to-fly ratios. This is particularly valuable for aerospace components produced in aerospace and aviation applications, where titanium scrap is costly and machining time is long.

Design Flexibility

Conventional subtractive methods are limited in creating internal channels or lightweight lattice structures. LENS technology enables complex geometries, topology optimization, and feature repair without full remanufacturing. Combined with precision finishing via CNC machining, LENS achieves both geometric freedom and high dimensional accuracy.

Mechanical Performance

LENS-printed Ti-6Al-4V parts may initially contain micro-defects due to rapid solidification. However, with post-process treatments such as hot isostatic pressing (HIP) and controlled heat treatment, mechanical properties can match or exceed those of forged components. Proper microstructure refinement improves fatigue resistance, creep strength, and stress corrosion cracking performance.

Lead Time and Repair Advantages

Traditional manufacturing requires full part production for any modification or damage repair. LENS allows local feature addition or damaged section rebuilding, extending part life without full remake. This is widely applied in turbine blade maintenance from single crystal casting and power generation systems.

Scalability and Production Volume

Traditional methods offer higher scalability for mass production, especially for simple shapes. LENS is most effective for low-volume, high-value components, prototyping, and repair applications—ideal for aerospace, oil and gas, and defense sectors, where performance and customization outweigh volume efficiency.