PyroGenesis, a Canadian metal powder producer, has officially confirmed Boeing as the aerospace OEM in its Ti64 metal powder qualification process, ending months of speculation. The company’s Ti64 “coarse” metal powder has successfully met Boeing’s technical standards, positioning PyroGenesis in the final stages of the approval process.
P. Peter Pascali, President and CEO of PyroGenesis, emphasized the significance of this achievement. “PyroGenesis is proud to be in the final queue for achieving supplier status with Boeing, one of the largest, most notable, and most advanced companies in the world. What’s exciting for PyroGenesis is that Boeing has shown itself to be a true innovator in the additive manufacturing arena, having spent more than three decades using 3D printed parts.”
Produced using PyroGenesis’ NexGen™ plasma atomization system, the Ti64 powder, with a particle size range of 45µm to 150µm, is primarily used in additive manufacturing processes such as Electron Beam Melting (EBM) and Direct Energy Deposition (DED).
Final Steps Through Boeing’s Supplier Qualification Process
In preparation for final approval, PyroGenesis has announced its continued efforts to refine its processes in alignment with Boeing’s evolving technological requirements. The company has also strategically stockpiled Ti64 “coarse” titanium powder to ensure project readiness once it is officially designated as a supplier.
While the approval process is expected to conclude in the first quarter of 2025, the timeline may be influenced by external factors beyond PyroGenesis’ control. P. Peter Pascali acknowledged that the complexity and duration of such approval procedures are standard in mission-critical manufacturing industries.
PyroGenesis Advances in Metal Powder Production
In 2019, PyroGenesis introduced the NexGen Plasma Atomization System, an evolution of the original Plasma Atomization Process (PAP) developed by the company in 1995. The company explained that the NexGen system represented a significant leap forward, overcoming earlier challenges in particle size distribution, efficiency, and scalability.
In 2021, PyroGenesis successfully tested its Additive Manufacturing NexGen powder production line. The decision to delay commercial production allowed the company to refine processes, ensuring batch-to-batch consistency and enhanced particle size control. These refinements not only increased production efficiency but also lowered CAPEX and OPEX, setting the stage for scalable operations to meet increasing demand in the 3D printing sector.
In 2023, PyroGenesis received its first large-scale order for titanium metal powder—five metric tonnes (5,000 kg) of plasma atomized titanium powder for 3D printing. This order marked a significant shift from the company’s previous small-batch production model, illustrating both the growing demand for high-quality additive manufacturing materials and the company’s ability to meet these needs at scale.
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Featured image shows PyroGenesis titanium metal powder. Image via:PyroGenesis
