Process & application development


Simulation-Driven Excellence

From light weighting and topology optimisation to thermal management and fluid dynamics, our team utilises top-tier tools and expertise to refine your product designs, all while reducing manufacturing complications and costs, ready for serial production.


Fast Track Development

Leveraging our in-house laboratory, we employ various characterisation techniques, from metallography and optical density classification to surface texture measurements and powder moisture and flowability tests. This is complemented by extensive mechanical and corrosion testing through our trusted network of partners.


Advanced Materials

We are equipped to test new innovative materials in small quantities, scaling seamlessly with our multi-laser platforms that enable rapid material changeovers for heightened productivity.


Bespoke Heat Treatments

We can develop bespoke and tightly controlled heat treatments to maximise the benefits of the unique microstructures obtained from the LPBF process and thereby optimise mechanical performance in service.

Process & application development

What We Offer.

At Apex, our Process and Applications Development service is designed to elevate your products’ quality, productivity, and surface finish through optimised designs, LPBF parameters and laser scanning strategies.  

Tailored to your needs, whether you’re a seasoned operator or new to advanced manufacturing, our comprehensive guidance covers everything from powder management to post-processing solutions, all aimed at accelerating your operational efficiency.  

Partner with Apex, and together, we’ll navigate the intricacies of LPBF, ensuring you reap its benefits without bearing the brunt of its challenges. 


Why partner with Apex?

Our in-depth knowledge of LPBF hardware and processes isn’t merely academic—it’s forged from years of hands-on experience in pioneering roles within LPBF system OEMs. We’ve been instrumental in advancing technology from its nascent stages to the mature, reliable platform it is today. Complementing this technical acumen is our robust real-world manufacturing experience, positioning us uniquely to meet even the most complex technical requirements while optimising production costs.

Driven by an insatiable appetite for success, we operate around the clock to deliver superior quality within your required timeframes, ensuring you stay ahead in today’s fast-paced manufacturing landscape.


  • Titanium Alloys: Ti6Al4V Gr 23 ELI

    The Ti6Al4V GR23 ELI alloy is a high-purity titanium alloy distinguished by its low levels of interstitial impurities like oxygen, carbon, and nitrogen. Its exceptional strength-to-weight ratio makes it ideal for automotive and aerospace applications requiring lightweight structures. Enhanced ductility and fracture toughness, as well as strong corrosion resistance and biocompatibility, expand its use to surgical and dental applications.  

  • Aluminium Alloys: AlSi10Mg

    AlSi10Mg is composed of aluminium, enriched with up to 10% silicon, and traces of magnesium, iron, and other minor elements. Silicon contributes to the alloy’s enhanced hardness and strength by forming Mg2Si precipitates.

    An inherent oxide layer on the alloy’s surface provides substantial corrosion resistance, which can be further heightened through chemical anodizing. It is commonly used for heat exchangers and thermal management applications.

  • Steels: M300 Maraging Steel

    Maraging steels belong to a category of iron-based alloys characterised by a martensitic crystal structure. They derive their unique strength and hardness from the precipitation of intermetallic compounds during ageing, typically at around 500°C (900°F), rather than from carbon content. Nickel serves as the principal alloying element, supplemented by cobalt, molybdenum, and titanium. The alloy known as Maraging steel M300 is alternatively identified as 1.2709. 

  • Steels: 316L Austenitic Stainless Steel

    The 316L alloy is a specialised form of austenitic stainless steel, primarily composed of iron and alloyed with up to 18% chromium, 14% nickel, and 3% molybdenum, among other trace elements. Distinguished as an extra-low carbon variant of the standard 316 alloy, it offers enhanced resistance to sensitisation, which is carbide precipitation at grain boundaries. This feature contributes to the alloy’s commendable weldability and superior resistance to stress rupture and tensile strength at elevated temperatures. 

  • Nickel Super Alloys: IN625

    The IN625 alloy is primarily composed of nickel, enriched with up to 23% chromium and 10% molybdenum, among other subsidiary elements. A key feature of this alloy is the inclusion of niobium, which synergistically interacts with molybdenum to confer high strength and toughness in its annealed state. IN625 finds extensive utility across diverse industrial applications, excelling particularly in environments like seawater where robust corrosion resistance is imperative. IN625 is also resistant to high temperatures and shares similarities with IN718, an alloy valued for its exceptional tensile, creep, and rupture strength properties. 

  • Nickel Super Alloys: IN718

    The IN718 alloy predominantly consists of nickel, constituting up to 55% by mass, and is further alloyed with iron and chromium, each reaching up to 21%, among other trace elements. IN718 is distinguished by its high strength, remarkable corrosion resistance, and an operational temperature range extending from -250°C to 650°C (-418°F to 1200°F). Additionally, it possesses age-hardening capabilities. IN718 is highly versatile in industrial applications that demand robust tensile, creep, and rupture strength. It shares application niches with IN625, an alloy favoured for its high-temperature corrosion and oxidation resistance.

    The alloy’s exceptional weldability and crack resistance also make it a preferred material for additive manufacturing processes. 

An advanced manufacturing one-stop-shop


Seamless In-House Manufacturing

Offering end-to-end advanced manufacturing solutions, we ensure rapid production in a strictly regulated and fully traceable environment.


Unrivalled LPBF Expertise

Mastery over laser powder bed fusion (LPBF) hardware and post-process chains allows us to deliver superior-quality parts quickly and cost-effectively, especially for complex geometries that maximize functional performance.


Exceptional Material Options

Gain instant access to hard-to-process materials, such as aerospace-grade Titanium and Inconel alloys, along with a wide range of high-alloy tool steels.


Stringent Quality Assurance

Our rigorous process control and fully traceable workflows meet the highest quality standards, catering specifically to the heavily regulated aerospace and medical sectors.


Eco-Conscious Manufacturing

Leveraging zero-carbon energy sources, our additive manufacturing methods stand as one of the most environmentally friendly, with minimal waste generation.


Proudly UK-Made

We actively support local industries while advancing the global adoption of state-of-the-art advanced manufacturing technologies.

succeeding through collaboration

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