ADVANCED METALS MANUFACTURING - AMAERO’S EXPANSION
RETROSPECTIVE SERIES
HYDRA CONSULTING’S STRATEGIC ROLE IN AMAERO’S GLOBAL EXPANSION
Advanced manufacturing demands precision, innovation, and rigorous execution. For Amaero, a leader in metal additive manufacturing, expanding operations across three continents required more than just ambition—it required world-class planning and expertise. At the core of this global success was Hydra Consulting.
Hydra’s collaboration with Amaero exemplifies the critical role that strategic planning and technical acumen play in enabling international scale and operational excellence.
Laying the Groundwork: Facility Design and Pre-Build Enablement
One of Hydra’s most pivotal contributions to Amaero’s expansion was its leadership in facility layout and pre-build enablement. Hydra played a foundational role in the planning and design of titanium and superalloy atomisation facilities in Australia, the United States, and Abu Dhabi.
These high-performance facilities were designed to meet complex manufacturing demands while maintaining efficiency, safety, and scalability. Key contributions included:
Site and layout optimisation to maximise product flow and align with operational processes and equipment requirements.
Design validation and compatibility analysis, ensuring that spatial and structural constraints did not compromise functional outcomes.
Process-aligned layouts, integrating personnel, equipment, production, and utility flows for seamless operation from day one.
This pre-build precision gave Amaero the confidence to proceed with site acquisition and construction, assured that operational outcomes would be delivered efficiently and cost-effectively.
Integrated Manufacturing Services Tailored to Amaero’s Vision
Hydra Consulting’s deep expertise in manufacturing project services positioned them as a trusted partner at a critical phase in Amaero’s growth. From facility design to regulatory compliance, Hydra supported every facet of project delivery with rigour and foresight.
Notable highlights include:
Safe facility design, ensuring segregation of people, powders, and processes in line with industry best practices.
Environmental and operational compliance, with the preparation and submission of comprehensive applications for regional approvals.
Risk profiling and critical control point (CCP) design, embedding operational safety into the fabric of each facility.
By applying a manufacturing-first mindset, Hydra enabled Amaero to develop globally competitive facilities that are built for high performance and sustainable growth.
Navigating Safety and Compliance in High-Risk Environments
Hydra’s value extended beyond design—its experience in high-risk, high-compliance sectors proved essential in tackling the unique challenges of metal additive manufacturing. The production of superalloy powders carries inherent risks, requiring robust systems to manage environmental and occupational hazards.
Hydra delivered practical, compliance-driven solutions such as:
Specialised dust extraction and waste stream management systems
Utility infrastructure planning, including HVAC and compressed air systems
GMP and WHS-aligned operational frameworks that met or exceeded global safety and quality standards
By embedding regulatory compliance into every aspect of the design and build process, Hydra ensured that Amaero’s operations were safe, efficient, and future-ready.
Enabling Global Scale with Confidence
Hydra Consulting’s ability to navigate complex, multi-jurisdictional projects left a lasting impact on Amaero’s global journey. Their combination of strategic insight, technical excellence, and delivery capability enabled Amaero to:
Reduce project risk
Accelerate site development timelines
Maintain operational integrity at scale
Hydra’s involvement was not just about building facilities—it was about enabling Amaero’s vision for global leadership in metal additive manufacturing.
Your Partner in Advanced Manufacturing Growth
Hydra Consulting has proven that the right partner can transform manufacturing complexity into opportunity. For ambitious companies like Amaero, Hydra brings the clarity, precision, and executional strength required to deliver world-class manufacturing outcomes.
Whether you’re expanding across borders or enhancing your local manufacturing footprint, Hydra helps you:
De-risk facility investments
Navigate regulatory environments
Design scalable, high-performance operations
Looking to scale your advanced manufacturing operations?
Hydra Consulting offers the expertise, insight, and delivery capability to help you succeed—every step of the way.