INNOSPACE Develops Support-Free Titanium LPBF Process

Key Takeaways

• Support‑free titanium LPBF cuts build time by 2.5×.
• Cost per titanium part drops about 40% on pilot project.
• INNOSPACE leveraged advanced process control on Eplus3D machines.
• Method could be replicated by other LPBF operators with tuning.
• Potential industry shift toward support‑free metal printing.

Pulse Analysis

Additive manufacturing has become indispensable for aerospace, especially for complex titanium components used in rocket engines. Traditional laser powder‑bed fusion (LPBF) requires sacrificial support structures to counteract thermal distortion, adding material, post‑processing steps, and significant build time. These supports also increase the risk of defects and limit design freedom, prompting firms to seek more efficient solutions. The challenge is magnified with titanium, a high‑strength, high‑temperature alloy that is notoriously prone to warping during the rapid heating and cooling cycles of LPBF.

INNOSPACE’s new process sidesteps the support‑structure bottleneck by employing precise, real‑time process‑control algorithms on standard Eplus3D LPBF systems. By fine‑tuning laser power, scan strategy, and layer‑wise temperature management, the company achieved a 2.5‑fold reduction in manufacturing duration and a 40% cost saving on a recent customer project. The results echo Velo3D’s support‑reduction approach but are notable for being realized on commercially available equipment rather than bespoke hardware, suggesting a more accessible pathway for other manufacturers.

If the methodology can be transferred to other LPBF platforms, the ripple effect could be profound. Aerospace firms would see faster part turnover, lower material waste, and reduced post‑processing labor, all of which tighten supply chains and improve margins. Moreover, the ability to print complex titanium geometries without supports expands design possibilities, fostering innovation in propulsion and structural components. As more operators adopt similar tuning practices, support‑free metal printing may evolve from a niche capability into an industry norm, reshaping the competitive landscape of additive manufacturing.