3D Printing with Recycled Titanium: IperionX Produces Prototypes for U.S. Military Vehicles

The use of additive manufacturing is becoming increasingly important in military vehicle construction, particularly when it comes to weight reduction and resilient supply chains. Against this backdrop, IperionX has received a prototype order from American Rheinmetall. The order includes the production of 700 lightweight titanium components for heavy U.S. Army ground combat systems and has a value of approximately USD 0.3 million. According to the company, successful execution could lead to a significantly larger follow-on order.

The components are to be manufactured in the United States and are based on fully recycled titanium. IperionX relies on its proprietary, patented processes, Hydrogen Assisted Metallothermic Reduction and Hydrogen Sintering and Phase Transformation. This process chain is designed for additive and powder-based processing and enables titanium powder for 3D printing to be produced more cost-effectively than with conventional Kroll-based processes. This is particularly relevant for military applications, as complex geometries can be manufactured directly and components can be functionally integrated.

From a technical perspective, the focus is on replacing existing steel components with additively manufactured titanium parts. Depending on the component, IperionX expects a weight reduction of around 40 to 45 percent. In the case of heavy tracked or wheeled vehicles, this can amount to several hundred kilograms per platform. Reduced weight affects acceleration, range, and ground pressure, among other factors, and facilitates the integration of additional protection and sensor systems.

The order is also relevant in the context of U.S. industrial policy. Titanium is considered a strategically important material whose supply chains have so far been heavily dependent on imports. IperionX is positioning itself as a domestic supplier of primary titanium material.

Taso Arima, CEO of IperionX, said: “This order highlights the practical application of IperionX’s recycled titanium technologies in critical U.S. ground combat vehicles. As the only domestic producer of commercial primary titanium, IperionX is uniquely positioned to support domestic defense priorities with secure, low-carbon, and cost-effective titanium products that are manufactured entirely in the United States.”