Ti-6Al-4V (Grade 5, also Grade 23 ELI for medical) is the most-specified titanium alloy — in both wrought and additive forms. DMLS-printed Ti64 achieves tensile strength above 1,000 MPa after HIP + aging, with excellent biocompatibility, corrosion resistance, and strength-to-weight ratio that beats any steel or aluminum.
Ti64 is 3–5× more expensive than aluminum or steel DMLS. Choose it only when the properties justify it:
Aerospace structure. Flight-rated brackets, hinges, satellite components. Weight savings over steel (4.4 vs 7.8 g/cm³) and strength over aluminum (1,070 vs 460 MPa).
Medical implants. Hip stems, spinal cages, custom plates. ASTM F136 ELI grade (23) is standard for implants. Biocompatible, non-allergenic, osseointegrates when surface-textured.
High-temperature parts. Titanium retains strength to 350 °C. Turbine blades, exhaust components, rocket parts operating where aluminum would creep.
Corrosive environments. Seawater, chloride solutions, many acids. Ti64 outperforms most stainless steels — marine hardware, chemical processing, offshore.
Ti64 DMLS parts undergo several post-processing steps to reach rated properties:
Reduces residual thermal stress before removing from build plate. Skipping this causes parts to warp during cutting.
Closes residual micro-porosity. Required for fatigue-critical aerospace and medical applications. 900 °C at 100 MPa for 2 hours.
Solution at 950 °C, quench, age at 550 °C. Brings the alloy to peak mechanical properties. Non-aerospace applications can skip aging and use as-built+HIP properties.
As-built Ti64 has ±0.1 mm tolerance and Ra ~10 μm. Mating surfaces (bearing bores, sealing faces) are machined post-HIP to spec tolerances.
Ti64 DMLS pricing depends heavily on part volume, build density, and post-processing:
| Part size | Unit cost (1-10 qty) | Unit cost (50+ qty) |
|---|---|---|
| Small (<20 g) | $180–$400 | $80–$150 |
| Medium (20–200 g) | $400–$1,400 | $180–$650 |
| Large (200–1,000 g) | $1,400–$5,000 | $650–$2,500 |
HIP adds ~20% cost. Aerospace certification (AS9100D, full traceability) adds ~15%. Medical (ISO 13485) similar.
Upload STEP. We quote with HIP, aging, and finishing. AS9100D or ISO 13485 documentation available.
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