Engineers at RMIT University in Australia have developed a breakthrough titanium alloy that is not only stronger than standard 3D printed titanium but also about 29% cheaper to produce. By replacing the increasingly expensive vanadium in conventional titanium alloys with more readily available, lower-cost materials, the team has created a material that could reshape manufacturing in industries from aerospace to automotive — and potentially architecture, interiors, and product design.

A Leap Beyond Legacy Alloys

For decades, 3D printed titanium components have relied on Ti-6Al-4V, a proven yet costly alloy that limits the full potential of additive manufacturing. The new alloy addresses this by offering a uniform grain structure that avoids the column-shaped microstructures common in some 3D printed metals, which can lead to uneven mechanical performance. This improvement not only boosts strength and ductility, but also enhances reliability in demanding applications.

Lead researcher and PhD candidate Ryan Brooke explained that this development is “a full leap forward” rather than a small incremental improvement. The method also offers a faster, less wasteful, and more tailored approach to manufacturing — essential benefits for designers seeking sustainable production.

Cost Efficiency Meets Performance

The innovation lies in a new framework for selecting alloying elements specifically for additive manufacturing. This approach streamlines material development, reducing both time and expense while maximising mechanical performance. By eliminating costly vanadium, the team has created a more sustainable supply chain with reduced environmental impact.

The research also provides a predictive model for printed grain structures, allowing for more accurate control of material properties during manufacturing — a valuable asset for industries where precision and durability are paramount.

Potential for Design Innovation

While aerospace and medical device sectors are early targets for commercialisation, the alloy’s lightweight strength, corrosion resistance, and cost advantages could see it applied to custom architectural fittings, interior fixtures, product housings, automotive parts, and even premium packaging. Designers across these fields could benefit from greater creative freedom, reduced production waste, and improved material efficiency.

Collaboration Opportunities

The RMIT team is seeking industry partners across the supply chain to further develop the technology and bring it to market. By bridging high-performance engineering with cost-effective manufacturing, this innovation could open the door to new sustainable design possibilities in multiple sectors.

Source & photo: RMIT University