From Titanium Lattice to Review-Ready Parts

How do complex titanium structures move from CAD to real parts without waiting for a long conventional manufacturing route?

For a customer in Asia, the requirement was clear: a small batch of customized titanium parts with open lattice geometry. These were not simple solid shapes. The spherical and star-like structures included repeated openings, fine struts, and complex internal spaces that needed to remain stable after printing and post-processing.

For this kind of project, speed matters. But speed alone is not enough. The customer needed a manufacturing partner that could respond quickly, review the design, choose the right process route, and make sure the finished parts were ready for practical evaluation, not just printed and shipped.

Manufacturing Route

Mastars selected titanium metal 3D printing because these geometries would be difficult to produce efficiently with conventional subtractive machining. The open lattice structure, internal spaces, and repeated patterns made additive manufacturing a more suitable route for low-volume customization.

But the project did not stop after printing.

After the parts were built, the next steps focused on making them clean, stable, and presentable. Loose powder had to be removed from the lattice openings. Support contact areas and build marks needed to be handled carefully. Surface finishing was also added to improve the consistency of the printed texture.

For Mastars, the key was not only to produce the shape, but to control the full route: design review, titanium printing, powder removal, support handling, surface finishing, inspection, packaging, and delivery.

Meeting the customer's requirement meant making the parts.

Exceeding the customer's expectations meant making them ready for review when they arrived.

What Was Controlled Before Delivery

Before delivery, the focus was not only on the printed shape but also on whether each customized part was ready for customer review.

Before delivery, we focused on these key checks:

• 1 titanium metal 3D printing route used for customized low-volume parts

• 2 visible geometry types completed: lattice spheres and star-like structures

• 5 post-processing controls covered: powder removal, support handling, surface cleaning, surface finishing, and final inspection

• 3 delivery checks completed: appearance, structural completeness, and packaging condition

• No dedicated tooling required before small-batch review

Why This Matters Beyond One Project

This type of requirement is becoming more common when product teams need to test complex metal structures without waiting for long development cycles or conventional tooling preparation.

Similar needs can appear in:

• Aerospace — lightweight titanium lattice structures and concept parts
• Medical Devices — porous structures and customized metal components
• Robotics — lightweight structural parts with complex geometry
• Industrial Design — premium metal samples and design validation parts
• Engineering R&D — small-batch functional prototypes for testing

For Mastars, this project reflects a simple manufacturing logic: quick response is only the beginning. Real delivery capability comes from controlling what happens after the first print.

Is your team also developing complex metal parts that need to move quickly from design to physical validation? Mastars can support customized low-volume manufacturing with a full process route from engineering review to final delivery. Get a quote!

Mastars, the most trusted one-stop manufacturing services provider for low-volume production worldwide!