Hyperion Secures Rights to GSD Technology for 3D Printing
Titanium 3D PrintingCMTE

Hyperion Secures Rights to GSD Technology for 3D Printing

Charlotte North Carolina based Hyperion has secured the exclusive rights to the patented Granulation-Sintering-Deoxygenation technology developed by Dr

Charlotte North Carolina based Hyperion has secured the exclusive rights to the patented Granulation-Sintering-Deoxygenation technology developed by Dr Z Zak Fang for producing zero carbon, low-cost spherical titanium powders. GSD offers major advantages in the production of spherical titanium for use in 3D printing, including

1. Production of titanium and titanium alloy powders with low oxygen, controllable particle size and excellent flowability

2. Higher manufacturing yields than current processes, leading to significantly lower costs

3. Energy efficient process leading to a zero carbon process when coupled with renewable power

4. Ability to utilize lower cost and sustainable feedstocks including recycled titanium metal powders/scrap or HAMR titanium powders

The combination of producing titanium metal via the HAMR process is followed by the production of titanium spherical powders via the GSD process has the potential to substantially reduce the total cost of titanium powders for 3D printing, opening up many potential new markets. The combination of these technologies has the potential to disrupt not just the high value titanium metals and powders market, but also the far larger aluminum and stainless-steel markets.

The GSD manufacturing process steps are

1. Titanium metal or alloy is hydrogenated to make friable hydride and is then milled into fine particles

2. The fine hydride particles are granulated into spherical granules in the desired size range using spray-drying

3. The spherical granules are sintered to produce densified spherical titanium powder

4. The densified spherical titanium powder is deoxygenated with magnesium to reduce the oxygen content to product specifications

5. The GSD technology can also introduce desirable alloying ingredients with the titanium hydride powder made in Step 1 to make titanium alloys

Dr Fang is a Professor of Metallurgy at the University of Utah. The HAMR and GSD technologies were developed, in part, with the financial support provided by the Advanced Research Project Agency-Energy of the US Department of Energy from 2014-2019. The Company is making significant progress with Dr. Fang and his team in Utah on both the HAMR and GSD technologies and expects to make key updates, including:

1. HAMR powder production using the company’s titanium minerals from the Titan project

2. Commencement of GSD powder production from HAMR titanium powders and/or titanium recycled scrap

3. Techno-economic assessment for the scale up of production of titanium metal and powders

Hyperion’s vision is to utilize these sustainable technologies and accelerate the rapid penetration of titanium in current and widespread applications in next generation mobility. The light weighting of trucks, trains, drones and electric vehicles will lead to a quantum leap in the energy efficiency of these vehicles and will be large, high growth new markets for titanium.

Titanium has exceptional material properties including high strength, light weight, superior corrosion resistance and leading biocompatibility versus other metals. Producing high quality spherical powders from titanium and titanium alloys is one of the critical building blocks for the rapidly growing, industrial scale, 3D printing / additive manufacturing sectors. Additive manufacturing with titanium can provide many benefits to the medical, aerospace, EV, space and defense sectors, including

1. Enhanced performance and sustainability by producing strong, lightweight parts that have high levels of corrosion resistance and are 100% recyclable

2. Reduced production lead times through iterative, software led design and rapid printing

3. Reduced waste and cost of producing a part - with scrap rates of less than 10% compared to over 90% for complex milled parts

4. In medical applications, titanium powders allow the rapid production of made-to-measure medical implants that are strong, lightweight, and critically, biocompatible

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