From Planes to Surgery Rooms: New 3D-Printed Titanium Could Change Everything

Efe Udin

August 13, 2025

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A group of engineers from RMIT University has created a new kind of 3D-printed titanium that could transform how we build things in industries like aerospace and medicine. This titanium is not only stronger than the common alloys in use today, but it is also more flexible and costs about one-third less to produce.

The strength and lightness of Titanium make it extremely valuable, which is why it’s a perfect material for manufacturing aeroplanes, spacecraft, and even medical implants. But due to its high cost, the material is not common. The new method from RMIT could open the door for more affordable, high-quality titanium parts.

Why This Matters

The difference between 3D-printed titanium and machined titanium has been a challenge. It is cheaper to use Machined titanium to produce consumer electronics like phones and laptops, but it lacks the design freedom of 3D printing, while 3D-printed titanium makes way for complicated designs, but is more expensive.

But with this new process the engineers developed, they have found a way to make 3D-printed titanium both stronger and cheaper, which will result in a 29% drop in production costs while keeping quality intact.

How They Did It

One of the main problems with regular 3D-printed titanium is that the internal grain structure is uneven. These column – shaped microstructures can create weak spots, making the metal less reliable. The RMIT team came up with a new design approach. The new design creates titanium alloys with a uniform grain structure. This makes it stronger and more flexible. According to lead researcher Ryan Brooke, the team has managed to solve a key technical problem while also lowering costs.

What’s Next

A plan is ongoing to focus on specific areas such as aerospace components and medical devices. These are the areas that really need the strength and lightness of titanium. Also, a provisional patent for the titanium manufacturing process has been filed by the university. However, they need industrial partners and investors to bring this technology to life.

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