MPW’s DirectPowder™ Titanium Meets Key ASTM Benchmarks for Aerospace Additive Manufacturing

• DirectPowder™ CP Titanium Grade 2 meets all ASTM B384 benchmarks for L-PBF
• Mechanical properties exceed Grade 2 and approach Grade 4 titanium standards
• Validation builds on prior cold spray success, showing multi-process versatility
• Hundreds of kilograms produced with consistent oxygen control and purity
• Third qualification underway targeting structural repair applications with UDRI

DirectPowder™ Surpasses Structural Standards for Aerospace Use

Metal Powder Works Limited (ASX:MPW) has cleared a significant hurdle in additive manufacturing with independent tests confirming its DirectPowder™ CP Titanium Grade 2 feedstock meets all ASTM B384 structural benchmarks for Laser Powder Bed Fusion (L-PBF). The testing revealed ultimate tensile strength of 112 ksi, yield strength of 94 ksi, and elongation to failure of 29%, comfortably exceeding the minimum Grade 2 requirements and even reaching the mechanical thresholds of Grade 4 titanium, all while maintaining Grade 2 oxygen levels (≤0.25%).

This achievement is notable because ASTM B384 is a standard originally written for wrought titanium, not additive manufacturing powders, making MPW’s results a strong signal for qualification in aerospace and defence sectors. The company’s patented room-temperature DirectPowder™ process preserves source bar purity and reduces batch variation, enabling this performance leap.

Multi-Process Validation Strengthens Market Position

These L-PBF results build on earlier validation with HAMR Industries’ cold spray additive manufacturing (CSAM), which achieved an 83 ksi ultimate tensile strength using MPW’s powder with air as the carrier gas, a cost-effective alternative to nitrogen or helium. Together, these outcomes demonstrate MPW’s unique capability to supply a single feedstock that meets structural handbook values across fundamentally different additive manufacturing processes, a feat uncommon in the metal powder supply market.

MPW Managing Director John Barnes highlighted the cost and quality advantages: "MPW can supply qualification-grade CP titanium at lower cost than atomised or HDH alternatives at equivalent or better oxygen control and purity, with better lot-to-lot consistency." This combination positions DirectPowder™ for broad specification across customer programmes.

MPW’s production has already delivered hundreds of kilograms of compliant powder, all meeting the stringent Grade 2 oxygen specification without fines or satellites, reinforcing its commercial readiness. These developments come on the back of a strong growth trajectory, including a recent surge in CP-Ti orders and key defence partnerships, which have expanded MPW’s customer base and product portfolio significantly tripled CP-Ti orders.

Ongoing Qualification and Repair Applications

Beyond production and testing, MPW is advancing a third qualification program with the University of Dayton Research Institute (UDRI), under contract from the US Air Force Rapid Sustainment Office. This program targets structural repair applications, potentially opening new government-contracted opportunities. Updates on this initiative will be pivotal for assessing MPW’s penetration into defence repair markets.

While the company has yet to disclose specific timelines for customer qualification completions, the combination of mechanical performance, production scale, and multi-process validation marks a compelling step forward. MPW’s approach contrasts with typical powder suppliers who certify chemistry and particle size but not the mechanical properties of parts made from their powders, underscoring the technical and commercial edge DirectPowder™ offers.

Bottom Line?

MPW’s DirectPowder™ has demonstrated a rare blend of mechanical excellence and manufacturing versatility that could accelerate aerospace qualification and broaden its market footprint.

Questions in the middle?

• How quickly will aerospace and defence customers move to formally qualify DirectPowder™ for critical structural components?
• What impact will MPW’s lower-cost, high-purity powder have on the competitive landscape for titanium additive manufacturing feedstock?
• Will the UDRI structural repair program translate into sizeable government contracts that materially boost MPW’s revenues?