Feedstock for the Factory of the Future.
At Layrr Materials, we understand that "Metal 3D Printing" isn't a single technology—it is a spectrum of complex physics. A powder that performs perfectly in a Laser Powder Bed system might fail catastrophically in a Binder Jetting machine.
We engineer and classify our powders by Process Capability. Whether you are melting with lasers, fusing with electron beams, or bonding with chemical agents, we have the specific cut and morphology to stabilise your build.
1. Laser Powder Bed Fusion (LPBF / SLM / DMLS)
The Precision Standard.
The majority of metal AM relies on spreading thin layers (20–60µm) of fine powder and melting them with a focused laser. This process demands the highest consistency in particle shape.
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The Challenge: Irregular particles cause friction during re-coating, leading to "short feeds" and porous parts.
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The Layrr Solution: We supply Gas Atomised, High-Sphericity powders with a tightly controlled 15–45µm or 20–63µm cut. Our surface-engineering technology ensures zero clumping, allowing for perfect packing density even with cohesive materials like Aluminum.
Key Materials:
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Lightweight Structures: AlSi10Mg, Scalmalloy® (Aerospace Brackets, Heat Exchangers).
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High-Temp Superalloys: Inconel 718, Hastelloy X (Turbine Blades, Combustion Liners).
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Medical: Ti-6Al-4V Grade 23, CoCrMo (Implants, Dental Copings).
2. Binder Jetting (BJT)
The Mass Production Engine.
Binder Jetting is moving AM from prototyping to mass manufacturing. By selectively depositing a liquid binding agent onto a powder bed, it creates "green parts" that are later sintered in a furnace.
The Challenge: Because there is no laser melting during printing, the "green part" strength relies entirely on powder packing. Poor flow results in weak parts that crumble before sintering.
The LAYRR Solution: Our Binder Jetting grades feature optimised multimodal distributions to maximise Tap Density. This ensures that when the binder cures, the part has enough structural integrity to be handled and depowdered.
Key Materials:
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Industrial Components: SS 316L, 17-4 PH (High-volume brackets, fittings, and sensor housings).
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Hard metals: WC-Co, W50/Co50 (Cutting tools and wear parts).
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Conductive Parts: Pure Copper (Induction coils, Heat sinks).
3. Electron Beam Melting (EBM)
The High-Energy Approach.
Using an electron beam in a high-vacuum, high-temperature chamber (up to 1000°C), EBM is designed for reactive materials and stress-free parts.
The Challenge: The powder must be conductive and resistant to "smoking" (electrostatic scattering).
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The LAYRR Solution: We provide coarser cuts (typically 45–105µm) with specific conductivity characteristics. Our pre-alloyed powders are chemically pure to prevent outgassing in the vacuum chamber.
Key Materials:
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Orthopaedics: Ti-6Al-4V (Acetabular cups with porous lattice structures for bone ingrowth).
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Aerospace: TiAl (Titanium Aluminide) (Low-pressure turbine blades).
4. Directed Energy Deposition (DED) & Cold Spray
Repair, Clad, and Build Big.
DED blows powder into a laser melt pool to build large structures or repair worn components. Cold Spray shoots powder at supersonic speeds to bond via kinetic impact.
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The Challenge: Efficiency. If the powder doesn't melt or bond upon impact, it is wasted (low capture efficiency).
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The LAYRR Solution: We supply denser, slightly coarser powders designed for ballistic flight stability and maximum absorption of laser energy.
Key Materials:
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Repair Operations: Inconel 625, Stellite® 6 (Repairing turbine shafts and valve seats).
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Structural Steel: 4340, Maraging M300 (Large-scale structural ribs and armour).
Use Cases by Industry
| Industry | Primary Application | Recommended Material |
| Aerospace | Thrust Chambers & Injectors | Inconel 718 / CuCrZr |
| Medical | Patient-Specific Implants | Ti64 Gr 23 / CoCrMo |
| Automotive | EV Motor Housings & Heat Exchangers | AlSi10Mg / Al6061 |
| Tooling | Injection Moulds with Conformal Cooling | Maraging M300 / H13 |
| Oil & Gas | Downhole Drilling Tools (Stators) | 17-4 PH / Inconel 718 |
| Electronics | RF Shielding & Heat Sinks | Copper / AlSi10Mg |
Not sure which grade fits your machine?
Every printer has a unique "sweet spot" for powder size and flow.
Contact our Applications Engineers to match a Layrr powder to your specific hardware (EOS, SLM Solutions, HP, Desktop Metal, GE Additive, etc.).