The Erich Schmid Institute of Materials Science (ESI) enables in-house production of medical-grade titanium and customized implant manufacturing using ATO technology - an ultrasonic atomizer. This approach ensures precise particle size control, high powder quality, and reduced contamination risks. It supports additive manufacturing processes, accelerates alloy development, and enhances flexibility in advanced materials research while minimizing reliance on external suppliers.
In-House Medical-Grade Titanium Production and Customized Implant Manufacturing at ESI
Case study
Additive Manufacturing
About ESI
The Erich Schmid Institute for Materials Science (ESI), part of the Austrian Academy of Sciences, is an application-oriented research institute based in Leoben, Austria. As part of the materials science cluster at the University of Leoben - together with Materials Center Leoben (MCL) and the Polymer Competence Center Leoben (PCCL) - ESI contributes to both fundamental research and industry-relevant developments.
The institute focuses on structural materials (including steels, alloys, composites, and biological materials), materials for information technology (such as flexible metal–polymer systems and thin films), materials for energy and high-temperature applications (including refractory metals and intermetallics), and bulk nanocrystalline materials. A core strength of ESI lies in advancing the understanding of microstructure–property relationships through the combination of advanced experimental techniques and modelling across multiple length scales, from atomic structures to macroscopic components.
INTRODUCTION
In recent years, ESI has further developed its capabilities in lab-scale metal powder production and powder-oriented materials research. This expansion supports both fundamental studies on microstructure control and applied research in additive manufacturing, where powder characteristics such as composition, particle size distribution, and solidification conditions play a key role in determining final material performance.
THE CHALLENGE
ESI faced limited access to customized alloy powders on the open market, while external suppliers were often unwilling to atomize experimental compositions. This significantly constrained research on emerging alloy systems for additive manufacturing and slowed down iteration on new material chemistries. In addition, reliance on external suppliers created challenges for projects requiring rapid material changes, as well as strict control over contamination and powder quality.
