Titanium Ti-6Al-4V (Grade 5) is the most widely used titanium alloy in aerospace and automotive work, 3D printed by DMLS for parts that need to be strong and light. It is about as strong as steel at just over half the weight, resists corrosion in sea water and most environments, and stands up well to repeated loads. Printing adds lattices and hollow sections that take out even more weight. Aerospace, space, motorsport, medical device and sports equipment teams use it for brackets, impellers, suspension uprights, instrument components and bicycle parts.
How Titanium Ti-6Al-4V is manufactured
Titanium Ti-6Al-4V is manufactured using Direct Metal Laser Sintering (DMLS) on EOS M 290 systems, an industrial powder-bed process in which a laser melts fine titanium powder layer by layer in an inert argon atmosphere, which reactive metals like titanium require. Support structures anchor each part to the build plate, and a stress-relief heat treatment after the build reduces internal stresses and increases ductility. This allows complex geometries, internal channels and consolidated designs to be produced in one build, with repeatable quality from the first part to the last.
Upload CAD files to Forge Labs Steam for instant Titanium Ti-6Al-4V pricing and live manufacturability feedback, and fix issues before production.
Upload CAD files to Forge Labs Steam for instant Titanium Ti-6Al-4V pricing and live manufacturability feedback, and fix issues before production.
DMLS parts generally exhibit a slightly rough, matte finish due to the laser sintering process, resulting in a uniform surface texture. While this natural finish is sufficient for many functional applications, Forge Labs offers several post-processing options to enhance aesthetics, accuracy, and performance.
Support structures are carefully removed, and parts undergo shot peening to create a uniform, matte surface and help relieve residual stresses. Critical features may receive light machining for tighter tolerances.
Precision machining and polishing processes enhance surface quality, achieving tighter tolerances and smoother finishes for critical applications.
Automotive-grade coating that enhances aesthetics and durability. Each part is hand-finished with professional-grade equipment for exceptional adhesion and custom color matching.
DMLS Titanium Ti-6Al-4V enables lightweighting and customization strategies, from aerospace brackets to high-performance industrial hardware, with corrosion resistance and durability that hold up in most environments. From rapid prototyping to production runs, teams rely on it to maintain tight tolerances while reducing assembly complexity through consolidated part designs.
Our EOS M 290 systems achieve 99.9% density, producing parts that meet or exceed wrought titanium properties while enabling complex geometries impossible with traditional manufacturing.
After heat treatment, the DMLS process gives a fine α+β microstructure with high fatigue resistance, critical for aerospace, motorsport and industrial applications. The 40 µm titanium process is built for high fatigue strength without hot isostatic pressing, and HIP is available for fatigue-critical parts.
Every titanium build follows a documented process, with process records and heat treatment protocols, so mechanical properties and surface finish stay consistent from one batch to the next.
Aerospace
Light, strong propulsion and test hardware with 595 MPa fatigue strength at 10 million cycles.
Space & UAV
Topology-optimized brackets, fasteners and satellite parts, with part chemistry to ASTM F2924 and F3302.
Automotive & Motorsport
Light, fatigue-resistant suspension and chassis parts for racing and performance vehicles.
Clean Tech
Threaded tees, barbed fittings and valve parts in one piece, with excellent corrosion resistance.
Medical & Healthcare
Light, non-magnetic instrument components and fixtures for medical device teams.
Sports Equipment
Lattice skateboard trucks, bicycle parts and premium gear that stay light and durable.
Aerospace
Propulsion developers and test teams use DMLS for pump impellers, pitot rakes and test instrumentation, and choose Titanium Ti-6Al-4V where a part needs high strength- and stiffness-to-weight performance. Precision test and calibration hardware, gauges and lightweight sensor housings print with integrated features and internal channels in place, then are heat treated, HIPed or machined as the drawing requires. Heat-treated Ti-6Al-4V reaches 595 MPa fatigue strength at 10 million cycles, which suits hardware that sees cyclic loads on a test stand.
Space & UAV
Forge Labs makes titanium parts for space programs. Space and UAV teams use Titanium Ti-6Al-4V for topology-optimized brackets, lightweight fasteners, mounting structures and satellite components with integrated features, where low mass matters. Part chemistry complies with ASTM F2924 and F3302, the powder bed fusion specifications for Ti-6Al-4V and titanium alloy parts, which gives quality teams a recognized starting point.
Automotive & Motorsport
Racing and performance teams use Titanium Ti-6Al-4V for suspension uprights, wishbone brackets and custom driver safety components, where low weight and high fatigue resistance matter most. DMLS builds the topology-optimized shapes that take weight out of chassis and engine-bay brackets carrying repeated loads.
Clean Tech
Clean tech and process equipment makers order tees with NPT threads and hose barbs in Titanium Ti-6Al-4V. DMLS prints the threads in place, and critical threads or sealing faces can be machined afterwards on our hybrid route. Ti-6Al-4V is highly resistant to general corrosion in sea water, which gives water-handling fittings, offshore hardware, process instrumentation and chemical processing valves a long service life.
Medical & Healthcare
Medical device teams use Titanium Ti-6Al-4V for metal instrument components and fixtures, where its strength-to-weight ratio keeps hand-held tools light and DMLS builds ergonomic geometries in one piece. It is effectively non-magnetic, with a relative permeability of 1.00005, which suits hardware used near sensitive equipment.
Sports Equipment
Sports and mobility brands use Titanium Ti-6Al-4V for skateboard trucks, bicycle components and premium performance gear that needs durability at low weight. DMLS builds lattice and hollow sections in one piece, with walls down to about 0.4 mm, and parts can be machined, shot-peened and polished as built or heat treated for a finished look.
Values from the EOS Titanium Ti64 Grade 5 datasheet for heat-treated parts, tested to the standard listed with each property. Modulus, as-built hardness and maximum operating temperature come from the EOS Titanium Ti64 M 290 datasheets, and alloy constants EOS does not publish come from TIMET Grade 5 data.
Mechanical performance
Titanium Ti-6Al-4V delivers dependable strength and fatigue resistance, giving teams a proven DMLS baseline for production aerospace, motorsport and industrial parts. Its balanced mechanical profile handles demanding load conditions while preventing brittleness in critical applications.
The values are for heat-treated parts, which EOS recommends, and the vertical (Z) and horizontal (XY) rows show the slight anisotropy of laser-melted titanium. Parts keep their integrity under repeated stress, which suits aircraft structural components, precision mechanical components and racing suspension parts that need precise geometry and tight tolerances.
Material makeup
Low density makes sections lightweight yet durable, and near-full part density keeps critical features in tolerance and downstream finishing predictable. The defect percentage shows how little porosity remains in the printed metal.
The composition rows are the EOS powder limits, which sit within Grade 5 requirements. Hardness is the as-built value, measured before heat treatment, machining and surface finishing.
Heat performance
Titanium Ti-6Al-4V keeps useful strength up to its long-term operating limit, from engine-bay components to industrial equipment near heat sources. Design to the maximum long-term operating temperature; the melting range and beta transus are alloy constants that matter for heat treatment and HIP, not for service.
Its low thermal expansion keeps assemblies stable as they warm, and its low thermal conductivity means titanium holds heat locally rather than spreading it like aluminium.
Functional performance
Titanium Ti-6Al-4V conducts electricity, so parts can be grounded, but its resistivity is far higher than aluminium or copper, which makes it a fit for grounded housings and fixtures rather than current-carrying parts.
Its relative magnetic permeability is close to 1, so it is effectively non-magnetic for sensor mounts and instrument hardware near magnetic fields.
Compatibility data
EOS publishes no chemical resistance table for printed Ti-6Al-4V, so the ratings come from TIMET's corrosion data for titanium. A stable oxide film gives the resistance: oxidizing and neutral environments keep it intact, reducing acids break it down faster as concentration and temperature rise, and fluorides attack it directly. TIMET notes that Ti-6Al-4V is somewhat less resistant than unalloyed titanium and can be susceptible to stress corrosion cracking in chloride service under some conditions.
Chemical ratings are screening guidance; confirm them with application-specific testing before production release.
Compliance
EOS classifies the powder as ASTM B348 Grade 5 titanium. In EOS testing, heat-treated parts exceed the tensile minimums of ASTM F1472 for wrought Ti-6Al-4V.
Quality teams can start aerospace and industrial qualification from this supplier data, and flight approval of each part stays with its design owner.
Datasheets, design guidance and supplier documentation for Titanium Ti-6Al-4V.
Access the most recent datasheet and supporting documentation maintained by our engineering team.
Titanium Ti-6Al-4V datasheetExplore printable geometry recommendations, wall thickness tips, and finishing playbooks for DMLS.
View DMLS design guide
Titanium Ti-6Al-4V is manufactured using industrial-grade DMLS technology, providing high strength and precision for mission-critical applications. EOS production systems print dense, fatigue-resistant tooling and end-use components, from a single prototype to repeat production batches.
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