Additive manufacturing: process development, modelling, and prototyping for high-performance applications

TWI has been at the forefront of metal additive manufacturing (AM) for over 25 years, building deep expertise across process development, design optimisation, and prototype fabrication. Our work supports the full innovation chain — from fundamental research and modelling to industrial production and qualification.

We help companies exploit the full potential of AM, whether for new builds, repair, or remanufacturing, and provide end-to-end support covering design, material selection, process optimisation, testing, and certification. Our capabilities span laser powder bed fusion, directed energy deposition, wire arc AM, and other metal AM processes.

With a dedicated team of over 35 AM specialists and access to TWI’s wider network of materials, joining, and inspection experts, we deliver practical solutions to accelerate industrial adoption. We also contribute to international standards development and collaborate with global companies to advance qualification and certification pathways.

TWI’s modelling and simulation tools enable digital process optimisation, while our advanced testing facilities allow for both mechanical and non-destructive evaluation of AM components. These capabilities are particularly valuable for aerospace and space systems, where lightweight structures, high integrity, and thermal performance are critical.

Whether you need to develop new AM processes, optimise part performance, or prototype complex components, TWI can provide the expertise, facilities, and engineering insight to turn innovation into production.