Amaero Scales U.S. Metal Powder Production for Defense and Aerospace 3D Printing

Amaero Inc. is ramping up metal powder production in McDonald, Tennessee, giving U.S. defense and aerospace manufacturers a domestic source for the titanium and refractory alloys used in metal 3D printing. The company now operates three Electrode Induction Gas Atomization (EIGA) systems, producing roughly 480 metric tons of titanium alloy powder and 200 metric tons of refractory alloy powder per year.

Why Powder Supply Matters

Metal additive manufacturing depends on more than just printers. The quality and consistency of the powder going into those machines determines whether a part holds up under extreme heat and pressure. For defense programs in particular, the U.S. is trying to reduce reliance on foreign suppliers for critical materials. Amaero is positioning itself as a domestic alternative, producing spherical titanium and refractory powders at scale.

C103 and High-Temperature Alloys

Amaero's product lineup includes C103, a niobium alloy designed for high-temperature applications such as rocket propulsion and defense engine components. The material can survive conditions that would weaken standard alloys, but producing it as a consistent, high-quality powder is difficult. Through the America Makes-supported MATCHAS program, Amaero rapidly qualified C103 powder to help lower the cost of high-temperature AM parts.

Beyond Powder: PM-HIP Components

Amaero also uses Powder Metallurgy Hot Isostatic Pressing (PM-HIP) to produce near-net-shape metal components. The process subjects powder to high heat and pressure inside a shaped container, yielding dense parts with properties similar to forged components. For defense manufacturers facing long lead times for cast or forged parts, PM-HIP offers a faster path, especially for low-volume replacement parts. Amaero is using this capability to support the U.S. submarine and maritime industrial base.

Looking Ahead

The company plans to double its powder production capacity over the next two to three years. It is also working with ASTM on research to improve titanium powder yield and recycling using EIGA technology. As the U.S. continues investing in additive manufacturing for defense and aerospace, domestic powder capacity is becoming a strategic priority. Amaero's expansion in Tennessee is one direct response to that demand.