Knowledge Base

Objectives, background and challenge

The study conducted jointly by Tekna and Renishaw aimed to design, produce, and validate a coarse-grained Ti64 titanium powder for use in laser powder bed fusion (LPBF) additive manufacturing processes. The main objective was to enhance overall production efficiency while reducing the costs associated with traditional fine titanium powders. By optimizing particle size distribution and leveraging Tekna’s proprietary RF induction plasma atomization process, the project sought to deliver a more economical and easier-to-handle powder that remains fully compatible with Renishaw’s LPBF systems, while maintaining the mechanical properties, surface quality, and consistency required for advanced industrial applications.

The main challenge lay in the high cost and operational complexity of fine titanium powders, which limit both the profitability and safety of additive manufacturing. Such fine powders create production bottlenecks, increase exposure risks to metallic dust, and require significant investments in safety and logistics infrastructure. The key issue, therefore, was to develop a coarser powder that would enable thicker print layers without compromising part precision or quality. The success of this development was expected to not only boost productivity and process sustainability but also make titanium additive manufacturing more accessible to cost-sensitive markets.