What’s the cost difference between CNC aluminum and titanium parts?

Key cost drivers between aluminum and titanium

From a manufacturing perspective, CNC titanium parts are typically two to four times more expensive per piece than comparable CNC aluminum components, driven by three main factors: raw material price, machining time, and tooling wear. Aluminum alloys, such as 6061 and 7075, offer a lower cost per kilogram, can be cut at higher speeds, and allow for shorter cycle times, making them ideal where weight, corrosion resistance, and medium strength are sufficient. A well-optimized part routed through a flexible CNC machining service and CNC milling service can keep aluminum unit costs very competitive for both prototypes and series production.

Titanium offers superior specific strength, fatigue resistance, and corrosion resistance, but it machines more slowly, generates more heat, and requires rigid setups and premium tooling. Internal threads, pockets, and thin walls require careful control through CNC turning services and multi-axis machining services, which increase spindle time and fixture sophistication. As a result, even with similar geometry, titanium versions of a part naturally carry a higher cost baseline.

Surface finishing and lifecycle economics

Finishing requirements influence the total cost gap. Many aluminum parts only require an as-machined surface finish plus hard anodizing for wear and corrosion protection, which is fast and economical for large batches. Decorative or protective CNC powder coating finish is also straightforward.

Titanium parts, although more expensive to machine, often require fewer heavy coatings because alloys like Ti-6Al-4V (TC4) and Ti-6Al-4V ELI (Grade 23) inherently offer excellent corrosion and fatigue resistance. In critical structures, advanced grades such as Ti-5Al-5V-5Mo-3Cr (Ti5553) can reduce weight or part count, partially offsetting higher piece price through performance and lifecycle benefits.

To define a realistic cost-performance balance, early-stage CNC machining prototyping with both materials is an effective way to compare machining behavior, achievable tolerances, and required finishes before freezing the final specification.

Application-based selection: where each material makes sense

In Aerospace and Aviation, titanium is used for load-bearing, fatigue-critical, and temperature-exposed components, while aluminum 6061 or Aluminum 7075 is suitable for housings, covers, and non-primary structures. In the Automotive Industry, aluminum remains the cost-effective choice for brackets, motor housings, and cooling components, while titanium is reserved for niche high-performance or motorsport parts. In Medical Device applications, biocompatible titanium grades provide clear functional justification despite higher machining cost, especially where implantable or high-precision interfaces are involved.

In short, if stiffness, strength, corrosion resistance, or biocompatibility requirements can be met with Aluminum 6061 or similar alloys, CNC aluminum will be significantly cheaper. When the operating environment or safety factors truly demand titanium performance, its higher machining cost is usually offset by reduced weight, longer service life, and fewer failures, rather than by piece price alone.