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Thanks rakuday, I wasn't aware of any weakness along the vertical axis. I have taken on board all the good advice posted and don't think AM is suitable for my part. Interestingly, having had a brief look at investment casting and hot isostatic pressing, this may be a route to explore...

Machining from a forged billet (after stress relieving) will have better mechanicals over casting the part (to my knowledge). I wanted to look for a viable option to reduce waste, tooling, and manufacturing time. Additive manufacturing sounded like the answer.

Thanks cloa and Edstainless I will look into those processes. For people who may also be interested, I've also done a little more digging and found a company called ExOne who produce a machine called the M-7. This has a build envelope of 780 x 400 x 400 mm, but prints a binder onto the powdered...

edstainless, i don't know a lot about welding, brazing or diffusion bonding. the part will be subjected to pressures around 40-60,000 psi and high temperatures, will it hold up against these without failing?

i dont really want to redesign the part to do this. im quite happy to stick with machining the part from a billet, but i wanted to explore this option first - in the interest of saving time and money.

looking to get a part prototyped using the above method. having read about the amazing cost effective process that is additive manufacturing (in all its various forms) i decided to give it a go, the problem though is size. all current systems seem to have a work envelope averaging 250 x 250 x...

thank you Chris, very much appreciated

not sure if this is the right section, please forgive if it is not. can anyone point me in the direction of the types of materials used on gym equipment handles. many thanks.

very helpful desertfox! exactly what i was after!!!

berkshire- that does sound like a very simple solution, that you for that.

thanks for the quick replies. desertfox - i am that bad at drawing it would just serve to confuse you more. a gas spring something like this (attached file) with the cylinder going through the middle of the gas...

i have done some searching online and can't find what i'm looking for. i'm not entirely sure that it is possible but thought i'd pose the question anyway (out of curiosity) a gas spring (doesn't matter if its push or pull type) with a hole in the middle - by which i mean so that it would fit...

has anyone any other suggestions? the dimensions cannot be altered but i need a ceramic barrier.

btrueblood - yes you are right, i misread some information. anything less than 1.7" isn't really possible. so back to square one - any suggestions?

i have found someone who can PVD coat my tube. thanks for the help

i am using 6-4 because of weight/strength properties. but i need a liner to reduce friction/cracking and with good corrosion resistance, which is why i want to line the 6-4 with a ceramic. hot gasses and a moving metal object will be passing through.

i was thinking more along the lines of PVD. but this is typically applied to the outside of a given solid. whereas i need to apply an even coating on the inside within the above dimensions.

how can i surface treat the inside of a titanium alloy (6al-4v) cylinder (dimensions 3/4" diameter, 16" length) with a ceramic coating?

TVP, thank you for your follow-up post, not sure why i hadn't considered this approach before. I will look into a multilayered design. this may allow a heat sink to be incorporated into the design to help reduce temperature therefore reducing thermal expansion. a ceramic lining could...

thank you for the reply TVP, can you suggest another material to aid in the reduction of thermal expansion and friction, and increasing rigidity and wear rate. has to cope well in an environment where temperatures will reach around 600deg F, varying pressures up to about 60-70,000PSI and...