The Challenge
Metal 3D-printed components are widely used in aerospace, energy, and industrial applications. However, they face significant reliability challenges due to oxidation during printing, internal stresses, micro-cracks, and surface porosity. Post-processing often fails to fully eliminate these weaknesses, leaving parts vulnerable to corrosion, fatigue, and thermal degradation—particularly in demanding environments and with complex geometries.
The TerraBarrier Solution
TerraBarrier’s inward-grown barrier layers mitigate the critical weaknesses of additively manufactured parts. Our coating system reduces surface porosity, seals micro-cracks, and enhances corrosion resistance—without altering the geometry or precision of the printed part. The barrier layer also stabilizes surface chemistry, improving resistance to thermal fatigue and oxidation.
Sustainability & Cost Benefits
- Extends usable lifetime of 3D-printed parts
- Enables broader adoption of additive manufacturing in harsh environments
- Makes lightweight designs more viable through surface strengthening
- Allows use of less expensive base alloys without sacrificing performance
Proven Performance
Validated with leading energy and aerospace stakeholders, and tested on stainless steel and aluminum alloy components. Independent testing confirms improved fatigue strength and corrosion resistance in AM parts.
Contact us to learn more.