Titanium TiAl6V4 in 3D Metal Printing

High-strength, corrosion-resistant, and significantly lighter than steel. Titanium TiAl6V4 is suitable for weight-optimized functional components where strength and operational reliability are more important than the lowest material cost.

High strength and low weight
Excellent corrosion resistance
Suitable for high-performance functional components

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Product Visualization, AI-Generated

Is titanium the right material for your component?

Titanium is particularly suitable when …

The goal is to reduce the weight of the component
high mechanical loads occur
Corrosion resistance is required
complex, weight-optimized geometries are planned
Function integration can replace conventional assemblies
the technical benefits justify the higher material and manufacturing costs

Consider alternatives if …

the lowest component price is the deciding factor
moderate strength and light weight are sufficient
very high operating temperatures may occur
Thermal or electrical conductivity is the primary requirement
the component is easy to machine and can be manufactured cost-effectively using conventional methods

Suitable Alternatives

Aluminum, when weight and cost-effectiveness are the top priorities. Learn more about aluminum
Inconel: When temperature resistance is critical. About Inconel
Copper, when thermal or electrical conductivity is required. All information about copper

Titanium in Comparison

Decision criterion	Titanium TiAl6V4	Aluminum AlSi10Mg	Stainless steel 1.4404	Inconel 718
Weight	very low	least	high	high
Strength	very high	medium	high	very high
Corrosion Resistance	very high	good	very good	very good
Temperature Resistance	medium	limited	medium	very high
Thermal Conductivity	rather low	good	low	low
Cost item	high	relatively inexpensive	medium	high
A typical decision	Lightweight Construction Plus Strength	cost-effective lightweight construction	robust standard application	High-Temperature Application

In short: Titanium is the right choice when aluminum isn't strong enough and steel is too heavy. For extreme temperature conditions, Inconel should be considered.

Titanium TiAl6V4 at a Glance

A lightweight material with high strength and excellent corrosion resistance—ideal for demanding applications.

Typical titanium components:

Lightweight mounts and structural components
high-strength fasteners
Flow-optimized components with internal channels
Custom-designed functional parts
Components for Corrosive Environments
weight-optimized small-batch components

Typical applications:

Aerospace,
Motorsports,
Mechanical Engineering,
Medical devices (supplied non-sterile),
Marine-grade, high-quality lightweight components.

Density	~ 4.36 g/cm³
Tensile strength_Rm	~ 1075 MPa
Yield strength_Rp0.2	~ 965 MPa
Elongation at break A	~ 10 %
Modulus of Elasticity E	~ 110,000 MPa
Hardness	~ 325 HV5
Max. Operating Temperature	~ 250 °C
Build Volume (Titan)	280 × 280 × 360 mm
Tolerances (Approximate Values)	±0.2 mm or ±0.2% (whichever is greater)
Surface	blasted / shot-blasted; CNC precision machining available upon request

The values listed are approximate. Actual properties may depend on factors such as component orientation, wall thickness, process parameters, and heat treatment, among others.

Designing Titanium Components for 3D Printing

In 3D printing with titanium TiAl6V4, the design affects not only manufacturability but also part quality, costs, and the amount of post-processing required. Therefore, part orientation, support structures, powder removal, and functional surfaces to be machined later should be taken into account as early as the development stage.

Cavities and internal channels

Internal channels and complex cavities are among the particular strengths of additive manufacturing. However, it must be possible to completely remove any unmelted metal powder after the manufacturing process.

Enclosed cavities should therefore be avoided. For internal structures, sufficiently large and easily accessible powder inlets must be provided. The shape, length, and configuration of the channels must allow for reliable emptying.

Wall thicknesses and delicate areas

Wall thicknesses must be tailored to the size, geometry, and load-bearing requirements of the component. Structures that are too thin or have a large surface area may deform during manufacturing. Solid sections, on the other hand, increase material usage, construction time, and thermal stress.

Uniform material distribution and smooth transitions are generally preferable to sharp changes in cross-sectional dimensions. Fillet radii can help reduce local stress peaks.

Overhangs and Support Structures

Overhanging areas require additional support structures, depending on their angle, length, and orientation. These structures stabilize the component during the construction process and dissipate process heat.

Since support structures must be removed after manufacturing, they should be placed on easily accessible and non-critical surfaces whenever possible. The orientation of the component therefore has a direct impact on:

the number of support structures required
the surface quality
the amount of post-processing required
the construction time and, consequently, the production costs
the location of mechanically and visually relevant surfaces

Holes, Threads, and Fits

Holes and threads can be incorporated into the design. If tight dimensional tolerances, defined fits, or load-bearing threads are required, mechanical finishing is often recommended.

To ensure this, the relevant areas should be designed with an appropriate machining allowance. This applies in particular to:

Fit holes
Thread
Bearing and Seal Seats
Planned Areas
Connection surfaces
precise contours

A technical drawing that includes tolerances and functional surfaces makes production planning easier.

Distortion and Thermal Stresses

Layer-by-layer melting and solidification result in significant local temperature differences. These can cause residual stresses and warping. Large, flat surfaces, abrupt changes in cross-section, and uneven material distribution are particularly critical.

These effects can be reduced through proper component orientation, design adjustments, and subsequent heat treatment.

Design data for testing

For the manufacturing review, you can submit your 3D model in STEP, STL, or 3MF format. For fits, threads, sealing surfaces, and geometric and dimensional tolerances, a technical drawing in PDF format should also be provided.

Are you still in the design phase? We review component orientation, critical geometries, post-processing, and potential cost optimizations before manufacturing begins.

Manufacturing, Build Volume, and Tolerances: Important Information for Optimal 3D Printing

Rapidobject uses titanium TiAl6V4 in powder-bed-based metal 3D printing. This material is particularly well-suited for complex, high-stress components that require a combination of high strength and relatively low weight.

Materials and Manufacturing Processes:

Manufacturing process: powder-bed-based metal 3D printing
Typical finish: sandblasted
Further processing: Heat treatment, HIP, tumbling, and CNC machining according to technical specifications

Post-processing Options

3D Printing

Heat Treatment/HIP	Stress-relief annealing; HIP, if necessary, to reduce porosity and improve toughness
Blasting/Trowalizing	even, matte finish
CNC Finish	Flat surfaces, holes, threads, sealing grooves
Labeling	Serial number/logo available
Documentation	Test report/measurement report available upon request

CNC Re-machining

Mating surfaces,
Drilling,
Thread,
Seal Grooves

– Everything from a single source. Just upload your drawing.

How do I get a quote?

Upload 3D data to

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You will receive a detailed price list for all materials and surface finishes.

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Tip: Upload 3D data and get a price quote right away

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Frequently Asked Questions About 3D Metal Printing with Titanium

When is titanium a better choice than aluminum?

Titanium (TiAl6V4) is particularly useful when high mechanical strength must be combined with low component weight. Compared to aluminum, titanium is therefore better suited for components subjected to higher loads and more demanding operating conditions.

If moderate weight, good thermal conductivity, and the lowest possible manufacturing costs are the primary considerations, aluminum may be the more economical solution. The decision should be based on load, temperature, corrosion, weight, and quantity.

How is titanium different from stainless steel?

Titanium has a significantly lower density than stainless steel, yet offers high strength. This makes it particularly well-suited for weight-optimized functional components.

Stainless steel may be a better choice when weight is not a major consideration and a robust, corrosion-resistant material is needed at more cost-effective terms. For both materials, the specific properties depend on the alloy, manufacturing parameters, and post-processing.

For which components is titanium suitable in 3D printing?

Titanium is particularly well-suited for complex components subjected to mechanical stress, where the goal is to reduce weight or combine multiple functions into a single component. Typical examples include:

Lightweight mounts and structural components
high-strength fasteners
Components with internal channels
topology-optimized components
corrosion-resistant functional parts
Custom small-batch production

Simple turned or milled parts, on the other hand, are not automatically good candidates for 3D printing. In such cases, it is important to determine whether conventional manufacturing is more cost-effective.

Up to what temperature can titanium TiAl6V4 be used?

The current materials page lists a maximum operating temperature of approximately 250 °C for TiAl6V4 titanium. This value should be considered a general guideline. [rapidobject.com]

The permissible operating temperature of a specific component also depends on the load, duration of use, environment, safety requirements, and heat treatment. In the case of continuously high temperatures, it should be determined whether a nickel-based alloy such as Inconel is more suitable.

What is the surface finish of titanium components immediately after 3D printing?

After additive manufacturing, titanium components have a rough surface due to the manufacturing process. At Rapidobject, the components are sandblasted as standard, resulting in a uniform, matte finish.

Depending on the requirements, additional machining operations such as Trowalizing or CNC finishing may be performed. Functional surfaces, fits, and sealing surfaces should be machined with precision.

Can threads and fits be printed directly?

Threads, holes, and fits can be incorporated into the 3D model. However, if specific dimensions or tight tolerances are required, subsequent machining is often recommended.

The relevant areas should therefore be designed with a machining allowance and marked on a technical drawing. For example, threads can be cut, holes can be reamed, or mating surfaces can be milled.

What data formats are accepted?

STL, STEP, and 3MF. For CNC machining, please also provide a technical drawing as a PDF.

How soon will I receive my quote?

Usually immediately after upload—complex assemblies are analyzed automatically.

What types of post-processing are possible?

Blasting, Trowalizing, Milling/Facing, Drilling, Threading, Surface Marking.

Are there any volume discounts?

Yes. For orders of more than 2 units, we offer automated volume-based pricing; for recurring orders, framework agreements are available.

Do you have any questions?

We’d be happy to provide you with personalized advice on your 3D printing project—from the initial idea to the finished part.

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Is titanium not the best fit for your needs?

Compare Titanium to Other Metals

Titanium TiAl6V4 combines high strength with relatively low weight and excellent corrosion resistance. These properties make the material technically superior, but it is not the most cost-effective solution for every component.

Therefore, determine which property is most important for your application.

Would you like to reduce weight and manufacturing costs?

Aluminum

Aluminum is suitable for lightweight functional components that require only moderate mechanical strength. Compared to titanium, aluminum can be more cost-effective and also offers good thermal conductivity.