Amaero expanded metal powder manufacturing in the U.S., producing titanium and refractory alloy powders at its facility in McDonald, Tennessee. The operation uses Electrode Induction Gas Atomization systems to create highly spherical feedstock for metal additive manufacturing and other advanced manufacturing processes. Amaero now operates three EIGA atomizers, including two for titanium and one for refractory alloys, providing annual capacity of about 480 metric tons of titanium alloy powder and 200 metric tons of refractory alloy powder.
The company has also supported America Makes-backed work through partner ADDMAN to qualify C103 niobium alloy powder for high-temperature applications and is working with ASTM International on Ti-6Al-4V powder production, including yield and recycling improvements. Beyond AM powders, Amaero uses powder metallurgy hot isostatic pressing to produce dense components for defense applications.
For manufacturers and defense contractors, the expanded domestic capacity could strengthen access to critical materials and support more resilient supply chains as U.S. additive manufacturing adoption grows.
Image Credit: Amaero
Key Themes Behind This Trend
- Domestic Powder Reshoring
- Localized production of titanium and refractory alloy powders reduces exposure to overseas supply constraints while supporting faster qualification cycles for advanced manufacturing.
- High-temperature Alloy Feedstocks
- Specialized powders such as C103 niobium create new pathways for components that withstand extreme thermal environments in aerospace, defense, and energy systems.
- Powder Recycling Optimization
- Improved yield and reuse methods for metal additive manufacturing feedstocks can lower material costs and make large-scale production more commercially viable.
Where This Applies
- Additive Manufacturing
- Expanded access to highly spherical EIGA powders strengthens the industrial case for 3D-printed metal parts in regulated and performance-critical applications.
- Defense Manufacturing
- Domestic powder metallurgy and hot isostatic pressing capacity enhances secure sourcing for dense, mission-critical components used in defense platforms.
- Aerospace Materials
- Advanced titanium and refractory alloy powders enable lighter, heat-resistant, and more complex parts suited to next-generation aircraft, spacecraft, and propulsion systems.
