Australian metal powders specialist Metal Powder Works Limited has formalized a Powder Partnership Agreement with Austal USA, a subsidiary of Australia’s largest shipbuilder, Austal Limited. The agreement strengthens an existing commercial relationship and establishes a framework for co-developing specialized metal powders for Austal USA’s additive manufacturing programs, including projects at the US Navy’s Additive Manufacturing Center of Excellence (AM CoE) in Danville, Virginia.
“We are delighted to formalise our partnership with Austal USA, operator of the US Navy’s Additive Manufacturing Center of Excellence and a critical supplier to the US Navy. This partnership positions MPW’s DirectPowder technology within a strategic naval supply chain initiative at a time when the US Department of Defense is making significant investments in additive manufacturing capabilities. With both companies manufacturing in the United States, we are well positioned to support the domestic defence industrial base and look forward to expanding our collaboration as Austal scales additive manufacturing across its naval programs,” said John E. Barnes, MPW CEO.
The agreement positions MPW within a critical US Navy additive manufacturing initiative, supporting NAVSEA objectives to expand domestic manufacturing capacity and enhance the supply chain for naval shipbuilding and sustainment.
Developing Custom Powders with DirectPowder
Under the partnership, MPW will use its patented DirectPowder Process—a production method that can be tuned to precise application requirements—to create custom alloy powders for Austal USA. Initial materials include MPW’s CuNi alloys, which already meet US Navy standards. Samples will be provided for testing, allowing iterative refinement to optimize performance.
MPW highlighted that its novel production process enhances supply chain resilience by reducing dependence on single sources and improving cost efficiency. Successful completion of the development program is expected to lead to a commercial offtake agreement, outlining minimum annual volumes, pricing, and lead times for ongoing powder supply.
“Austal USA is committed to advancing manufacturing technologies that strengthen our capabilities as a US defence prime contractor. Through our operation of the US Navy’s Additive Manufacturing Center of Excellence, we are at the forefront of deploying additive manufacturing solutions across the maritime industrial base. Our partnership with Metal Powder Works provides access to high-performance metal powders specifically optimised for these applications, and the DirectPowder Process offers unique flexibility to tailor powder characteristics to the exacting requirements of naval manufacturing,” said Dr. Scott Kasen, Austal USA Director of Advanced Technologies.
Powder Deals Expand U.S. Navy Additive Manufacturing Programs
Building on similar objectives to MPW’s partnership with Austal USA, Velo3D, an additive manufacturing technology company specializing in mission-critical metal parts, partnered with Linde AMT, a U.S.-based metal powders and coatings specialist, to supply domestically produced CuNi powder for the U.S. Navy’s Maritime Industrial Base Program. The collaboration combines Linde AMT’s Indianapolis powder production facility with Velo3D’s Sapphire XC large-format printer, enabling faster, more cost-effective production of essential naval components.
Additionally, Velo3D secured a $6 million contract to develop and qualify copper-nickel alloy specifically for its Sapphire printer line. The qualification program, which includes Velo3D’s large-format Laser Powder-Bed Fusion (LPBF) system, directly supports the Navy’s efforts to accelerate ship repair timelines and strengthen supply chain resilience, addressing the limitations of traditional casting methods.
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Featured image shows Austal USA’s shipbuilding facility. Photo via Austal USA.
