High-Performance Materials for the Industry of Tomorrow: Titanium & Nickel-Based Alloys in Additive Manufacturing

Introduction: Industry 4.0 Starts with the Right Material

Additive manufacturing is changing industrial production. Components are no longer only machined, forged, cast or welded — they can now be built layer by layer from metal powder or wire. This enables geometries that would be difficult, expensive or even impossible to produce using conventional methods: integrated cooling channels, bionic lightweight structures, complex brackets, patient-specific implants and high-performance aerospace components.

But the success of metal 3D printing does not depend on machine technology alone. The decisive factor is the material.

Two materials are particularly relevant for demanding applications: Titanium Grade 5 ELI / Grade 23 / 3.7165 and Alloy 718 / 2.4668. Both combine outstanding performance with strict processing requirements, making them ideal for high-end prototypes, test series and safety-critical applications.

For industrial companies, this means that additive manufacturing requires more than design expertise and printing parameters. It requires a reliable material strategy from the very beginning.

Technical Material Highlight: Titanium Grade 5 ELI / 3.7165

Titanium Grade 5 ELI, also known as Titanium Grade 23 or Ti-6Al-4V ELI, is a high-purity version of the widely used titanium alloy Ti-6Al-4V. Its material number is 3.7165.

The abbreviation ELI stands for “Extra Low Interstitials”. It refers to particularly low levels of interstitial elements such as oxygen, nitrogen and carbon. This controlled chemical purity is especially important for applications requiring high toughness, fatigue resistance and biocompatibility.

In additive manufacturing, Titanium Grade 5 ELI is highly attractive because it offers an excellent strength-to-weight ratio. This is particularly valuable in industries where every gram matters.

Typical applications include:

• patient-specific implants

• orthopaedic and dental components

• lightweight brackets for aerospace and space applications

• structural components with complex lattice geometries

• high-end prototypes with integrated functions

In medical technology, the combination of corrosion resistance, low density, high strength and defined purity makes Titanium Grade 5 ELI particularly valuable. In aerospace and space applications, the material enables lightweight structures that can reduce mass without compromising technical performance.

Technical Material Highlight: Alloy 718 / 2.4668

Alloy 718, also known as IN718 or Nickel Alloy 718, is a precipitation-hardenable nickel-chromium alloy. Its material number is 2.4668.

This alloy is known for its high strength, corrosion resistance and excellent performance at elevated temperatures. It is widely used in demanding environments where conventional stainless steels or aluminium alloys are not sufficient.

For metal 3D printing, Alloy 718 is especially relevant because it can be used for highly loaded and thermally stressed components. It is often selected where components must withstand heat, mechanical loads and aggressive operating conditions at the same time.

Typical applications include:

• turbine and engine components

• space and satellite parts

• high-temperature brackets and structural elements

• components for energy and process industries

• prototypes exposed to extreme mechanical and thermal loads

Alloy 718 / 2.4668 is therefore a key material for applications in which aluminium is too soft, stainless steel too heavy or titanium not sufficiently temperature-resistant.

Why Purity and Exact Chemical Composition Are Critical in 3D Printing

In conventional manufacturing, components are often produced from rolled, forged or drawn semi-finished material. The material properties are supported by established process chains, forming operations and heat treatments.

In additive manufacturing, however, the component is created directly during the production process — layer by layer. This makes the chemical composition of the starting material even more critical.

Even small deviations in oxygen, nitrogen, carbon, aluminium, vanadium, niobium, molybdenum, titanium or nickel can influence:

• microstructure

• crack sensitivity

• ductility

• fatigue strength

• corrosion behaviour

• heat treatment response

• final part approval

For titanium powders, the control of interstitial elements is particularly important. Excessive oxygen or nitrogen levels can increase strength but reduce ductility and toughness. For nickel-based alloys such as Alloy 718, precise chemical balance is essential to achieve reliable precipitation hardening, hot strength and creep resistance.

For additive manufacturing, this means:

Powder quality and batch stability are decisive.

A test series is only meaningful if the material batch is documented and reproducible.

Certificates and traceability are essential.

Especially in aerospace, space and medical technology, “similar material” is not enough.

Chemical limits must be tightly controlled.

Minor deviations can have major effects on qualification and approval.

Post-processing must match the alloy.

Heat treatment, HIP processing, stress relieving and

surface finishing must be aligned with the material and manufacturing route.

Industry Focus: Aerospace, Space and Medical Technology

Aerospace: Reducing Weight, Integrating Functions

In aerospace, every gram counts. Additive manufacturing enables components that are lighter and more functionally integrated than conventional designs.

Titanium Grade 5 ELI / 3.7165 is suitable for weight-optimised structural parts and brackets. Alloy 718 / 2.4668 is used where higher temperature resistance and mechanical strength are required.

Space: Maximum Performance with Minimum Mass

Space applications demand extreme reliability. Components must withstand vibration, temperature changes, vacuum conditions, launch loads and long service life requirements.

Additively manufactured titanium and nickel-based components can help reduce mass, integrate multiple functions into one part and simplify assembly.

Medical Technology: Individualisation with Maximum Material Control

In medical technology, additive manufacturing enables patient-specific implants, porous structures and complex geometries. Titanium Grade 5 ELI / 3.7165 is especially relevant because biocompatibility, corrosion resistance, strength and defined purity come together in one material.

In all three sectors, the rule is clear: failure is not an option. Components must not only perform technically — they must also be documented, reproducible and suitable for approval.

The TSH Advantage: More Than Material Supply

Taferner Stahlhandel is not only a supplier of materials. For innovation-driven projects, TSH acts as a procurement partner for demanding material requirements.

This is particularly important in additive manufacturing, where many projects do not start with large production volumes. Instead, development teams often need small batches, test quantities, special dimensions, sample materials or tightly specified grades.

TSH supports customers with materials such as titanium, nickel-based alloys, stainless steel, aluminium, copper, brass and bronze. Available semi-finished forms include round bars, flat bars, plates, tubes and forgings. The company’s strength lies in access to a global supplier network for fast delivery times and customised special solutions.

For R&D departments, technical buyers and project managers, this is a decisive advantage. Many innovation projects begin with practical questions:

• Can a small test batch be sourced?

• Is the required grade available with suitable documentation?

• Are alternative dimensions available faster?

• Can a prototype material be supplied without committing to large volumes?

• Can international sources help when local availability is limited?

This is where an experienced specialist partner adds real value. TSH can help classify requirements, evaluate procurement options and support customers early in the material strategy phase.

Economic Outlook: Additive Manufacturing Becomes a Strategic Tool

Metal additive manufacturing will not replace conventional production methods completely. But it will continue to grow in areas where geometry, weight, function and development speed are decisive.

It becomes economically attractive when it does more than simply copy an existing part. The real value lies in redesigning components for additive manufacturing.

Key economic benefits include:

• fewer individual components through functional integration

• lower weight through topology-optimised structures

• faster development cycles through prototyping

• small series without expensive tooling

• improved performance through internal channels or lattice structures

As a result, the role of material procurement is also changing. Instead of only comparing kilogram prices, companies must think earlier about material availability, batch quality, standards, certificates and scalability.

Conclusion: The Future Starts with the Right Material Strategy

Titanium Grade 5 ELI / 3.7165 and Alloy 718 / 2.4668 show where industrial materials are heading: lighter, more powerful, more complex and more closely tailored to specific applications.

In additive manufacturing, the material does not become important at the end of the project. It is decisive from the concept phase onward. Companies that consider purity, chemical composition, documentation and availability early can reduce development risks and accelerate the path from prototype to application.

Call to Action: Material Partner for Innovation Projects

Are you planning an innovation project in additive manufacturing, high-end prototyping or special materials?

Taferner Stahlhandel supports you in sourcing titanium, nickel-based alloys and other high-performance materials — including small batches, test quantities and difficult dimensions.

Send your enquiry with material grade, standard, dimension, quantity, certificate requirements and desired delivery date to TSH.

Start your innovation project with the right material foundation.

Disclaimer / Technical Note

All technical information, material data and application recommendations provided in this article are intended for general guidance only and are provided without warranty. The suitability of a material must always be assessed based on the specific application, applicable standards, operating conditions, medium, temperature and mechanical loads. Final approval must be carried out by the responsible planner, operator or qualified specialist.