PILOT #1A Manufacturing of Aluminium Catalytic Converters

Replacing steel and titanium with aluminium — and rethinking the entire manufacturing chain around it.

The Challenge

Catalytic converters used in air purification systems are currently manufactured using steel or titanium, processed through Laser Powder Bed Fusion (LPBF) or metal fused filament fabrication — techniques that require debinding and sintering and carry significant material and cost constraints.

These converters serve a wide range of applications: from air regeneration systems in the International Space Station to NOx reduction in automotive soot filters, down to air purification in agricultural facilities. Their performance is well established — reusable, low-maintenance, with conversion rates up to 50% higher than conventional alternatives and a 10% reduction in catalytic material usage.

The problem is cost. At current prices (800–2,600 €/kg for steel or titanium versions), this technology remains inaccessible for medium and lower-end markets. The manufacturing approach does not yet support the broader deployment these applications would require.

THE DIAMETER APPROACH

Circularity strategy

Redesign for recyclability and environmental impact reduction

AM process

Multi-Metal Deposition (MMD)

Valcun is investigating the substitution of steel and titanium with aluminium as the base material, manufactured through MMD.

Aluminium offers a weight reduction of at least 50% compared to steel and up to 66% compared to titanium, with a potential manufacturing cost reduction by a factor of 8 — bringing the price range to 100–300 €/kg and opening access to sectors currently excluded.

PARTNERS INVOLVED

Pilot lead. Process owner, manufacturing, LCA assessment, platform demonstration

EXPECTED OUTCOMES

  • Weight reduction of the converter: ≥50% vs steel, ≥66% vs titanium
  • Manufacturing cost reduction by a factor of approximately 8
  • Demonstrated recyclability and environmental benefit through LCA comparison
  • Validation of the DIAgonal Design for Environment tool against physical manufacturing data
  • Part ready for EU Digital Product Passport (EU DPP) integration

STATUS: IN PROGRESS

Initial catalytic performance and pressure drop tests have been completed on a first manufactured part (aluminium 4043, 20 mm height × 41 mm diameter). Results show comparable catalytic efficiency to the reference version. A second iteration — a square-section single-wall specimen adapted to MMD process capabilities — is in preparation for full mechanical characterisation.

This section will be updated as the pilot advances