A new manufacturing industry is emerging in the Bay of Plenty that could create $1 billion in revenue a year, with higher paid jobs for New Zealand workers, all through a low carbon footprint process.

At the Bay of Plenty Polytechnic in Tauranga, Titanium Industry Development is at the forefront of a new industry that could change the country's manufacturing landscape.

Using titanium powder produced by Tauranga based company Titanox, one of only a few companies in the world producing this form of titanium, Tida are creating titanium-based products that are lighter, more durable and more efficient through a power metallurgy process that uses skill and innovation instead of lots of labour and is overall more economical.

Tida chief executive Warwick Downing says they are currently working with companies in the medical, industrial and marine industries, making a range of parts from medical devices like heart valves and artificial joints, to fittings for boats.

'It is perfect as a medical material as it is non-toxic,” says Warwick.
'As a medical implant the titanium is similar in elasticity to bone and encourages integration with the bone, especially when the new titanium foam material is used. 'The foam is made the same density as the bone and allows the bone to regenerate through the implant.”

The corrosive resistant properties of titanium alloys also make them perfect for use in the marine industry.

'In a marine environment, stainless steel will corrode when in contact with carbon fibre, but a thin titanium nitride coating protects the stainless steel from corroding so it can be used in boating, shipping and jewellery.”

Warwick says the properties for titanium alloys include shape memory, which can be used in a range of medical and industrial applications.

'The alloy has a set shape and can be changed to another shape, but will automatically return to the original shape when a trigger temperature is reached.”

With this cutting-edge technology, Warwick says there is huge potential to work in the industrial, aerospace, aviation and automotive sectors and expects the industry will really take off in the next 12 months.

'The aim is to produce $1billion a year for the New Zealand industry, but to do this we need New Zealand companies to get behind the technology.

'There is already interest building from overseas companies.”
At the BOP Polytechnic facility, Warwick and his team are creating these new-age products through a process called powder metallurgy.

Powder metallurgy is a consolidation process that takes powder and converts it into solid forms. The process starts with the powder being tested to ensure it is of an appropriate standard. Using powder injection moulding the powder is then melted and lasered into the desired shape.

'Essentially metal parts can be made in the same way as you would make plastic ones, this is a more cost-effective way than machining them as it cuts down time and reduces waste.

'Because it is using less energy per part at a faster rate and reducing the amount of waste it is lowering the carbon footprint.”
Warwick says there is typically between 50 to 90 per cent waste with machine manufacturing, but there is only two per cent waste with this technology.

'This is one of the advantages of powder metallurgy.”
Warwick says titanium alloy powder metallurgy is a relatively new global process having been developed in the last 10 years, with the BOP facility opening last year.

Warwick says advanced manufacturing techniques will help create a competitive economy which will bring higher paid jobs and huge financial growth.

In order to be competitive on a global stage, however, Warwick says the skill level of people in New Zealand manufacturing needs to be increased.

'We need people to be upskilled in advanced manufacturing in order to understand this type of technology. The people that are will be invaluable in their engineering field and it will lead to higher paid jobs.

'This is why we are based at the Polytechnic, with our partners we can create a platform for New Zealand manufacturing to prosper.”