Renishaw, a UK-based engineering technology company specializing in metrology and additive manufacturing systems, has partnered with Tekna, a Canadian materials producer, to make titanium 3D printing more efficient and cost-effective. Their collaboration centers on a coarser-cut titanium alloy powder optimized for Laser Powder Bed Fusion (LPBF) systems. The larger particle size enables faster build rates, reduced material handling risks, and lower overall production costs for industrial users.
Tekna, headquartered in Sherbrooke, Quebec, develops advanced plasma systems and metal powders used in aerospace, energy, and additive manufacturing. Founded in 1990 as a research and development company by Université de Sherbrooke professors Maher Boulos and Jerzy Jurewicz, Tekna operates manufacturing sites in Canada and France, with additional sales offices in Asia under its parent organization, Tekna Holding ASA. As of late 2024, the group reported 185 employees worldwide.
Titanium alloys such as Ti-6Al-4V (Ti64) are widely used in aerospace and medical manufacturing because of their strength-to-weight ratio, corrosion resistance, and biocompatibility. However, fine Ti64 powders—typically 15 to 45 microns in size—used in LPBF systems come with challenges. Their production is costly, and their small particle size increases flammability and inhalation risks. Because these fine powders are classified as dangerous goods, companies must invest in containment, ventilation, and storage infrastructure, adding to total production costs and limiting titanium AM’s accessibility in cost-sensitive markets.
Both firms collaborated to determine whether coarser titanium powders could maintain material integrity while enabling faster printing. Tekna applied its radio-frequency (RF) induction plasma atomization process, in which titanium wire is fed into a plasma torch, melted, and transformed into droplets that cool into spherical powder particles. This continuous, consumable-free process minimizes contamination since no electrodes or gas jets touch the molten metal. The resulting powders exhibit high sphericity, uniform chemistry, and strong flowability—attributes crucial for repeatable AM production.
Using this method, Tekna developed and optimized a coarse-cut Ti64 variant. The British manufacturer’s materials team validated the powder through laser parameter optimization, density measurements, and flow testing to confirm its performance on commercial LPBF systems. According to Tekna, the powder allows for thicker build layers—around 90 microns compared with the conventional 30 or 60 microns—resulting in faster printing speeds without compromising part strength or surface integrity.
“By combining our expertise, Tekna has developed a large-cut titanium powder that supports Renishaw’s objective of increasing overall process efficiency for their customers, while also reducing direct costs associated with the powder,” said Amir Nobari, Technical Sales Manager at Tekna. “The coarser powder works seamlessly with Renishaw’s LPBF systems, enabling faster printing with thicker layers while preserving essential material properties.”
Its additive manufacturing division emphasized the joint testing phase that ensured reliability across applications. “Renishaw’s material qualification expertise was critical in ensuring that Tekna’s large-cut titanium powder performed optimally on our systems,” said John Laureto, Additive Manufacturing Business Manager at Renishaw. “Our collaboration allowed us to test rigorously and refine the material to meet the high standards required for reliable, high-quality AM. The benefits extend across multiple industries. In motorsport and automotive, it supports high mechanical strength while keeping parts lightweight. The powder is already being applied in aerospace and defense.”
The validated material offers measurable operational advantages. Coarser powders reduce atomization and sieving costs, improve yield, and generate less waste. Because they are not classified as hazardous materials, logistics and storage are simplified, lowering both compliance and transportation costs. Reduced dust formation also lessens health risks for operators, contributing to safer and more sustainable manufacturing environments.
Renishaw’s open-architecture AM systems enable users to customize layer thickness and exposure parameters to match specific applications. Combined with Tekna’s plasma-atomized powder, this flexibility allows for shorter production cycles and higher throughput. As metal additive manufacturing continues scaling toward serial production, the ability to print thicker layers without sacrificing quality supports broader industrial adoption.
Through this collaboration, both companies demonstrate how material innovation can directly improve cost efficiency, safety, and scalability in metal additive manufacturing. Coarser titanium powders such as Tekna’s new Ti64 variant represent a practical path toward faster and more sustainable production, expanding titanium’s use across aerospace, medical, and industrial sectors.
Help shape the 2025 3D Printing Industry Awards. Sign up for the 3DPI Expert Committee today.
Are you building the next big thing in 3D printing? Join the 3D Printing Industry Start-up of the Year competition and expand your reach.
Subscribe to the 3D Printing Industry newsletter to stay updated with the latest news and insights.
Featured photo shows Laboratory testing of titanium alloy powder flowability. Photo via Renishaw/Tekna.
