Metalysis expands research capability to meet advanced material demands
January 22, 2025

Metalysis, an end-to-end manufacturer of solid-state metal and alloy powders based in Rotherham, UK, has announced the installation of three new Gen 1 research units, building on its current capacity of the existing nine units. The additional equipment will expand its first-stage research capabilities by a third, and is reported to be in response to demand from advanced industries such as hypersonics, defence, clean energy (nuclear fission and fusion) and space.
“This need for substantial expansion is led by our partners and potential partners – particularly in the hypersonics and space sectors – who have sourced Metalysis as their global partner for the development and commercial supply of advanced novel materials,” explained Nitesh Shah, CEO of Metalysis. “As these innovative sectors grow, the need for novel advanced materials increases, and our Gen 1 units will allow us to work with partners on the required physical properties and chemical compositions of their advanced materials. Metalysis recently purchased a spheroidiser for in-house production of spherical powders and this expansion of our Gen 1s further expands our in-house capacity.”
Metalysis uses the patented FFC Cambridge electrolysis process—which reduces metal oxides in the solid state—scaled across Metalysis’ Gen 1 to Gen 4 units. Gens 1 and 2 are the R&D units based at the Metalysis Discovery Centre at the Advanced Manufacturing Park in Catcliffe, while Gens 3 and 4 are the commercial and industrial units based at the Metalysis Manufacturing Centre in Wath upon Dearne.
Each Gen 1 can produce grammes of output per machine per run and is the first stage in the Metalysis product development process. The Gen 1s are aimed at directly serving commercial clients’ advanced material development needs, producing low levels of output for proof of principle before the client’s requirements are elevated to Gen 2, Gen 3, or Gen 4 (which is capable of tens of tonnes of output per unit per year.)
Each Gen unit contains a crucible of electrolyte (calcium chloride, aka rock salt) and, traditionally, a carbon anode; variations in the anode are possible, dependent upon the off-gas being produced. The metal oxide acts as the cathode, and with heating of the rock salt between 650-950ºC and a voltage applied, the oxygen is released, gravitating to the anode, leaving a metal sponge. This sponge is then crushed, milled, and dried, producing a powder. The process is agnostic to oxide composition, meaning the Gen units are not constrained by product type.
In contrast to traditional melting processes for metal alloy powder production, electrolysis uses much lower temperatures and less energy as it is a single-stage process rather than a multi-stage one. Also, no hazardous chemicals are used during the Metalysis process.
In contrast to melting, Metalysis’s technology is also noted as being highly adaptable, allowing bespoke materials to be produced as directed by specific customer demand. This ability has seen Metalysis partner with global entities in sectors such as advanced electronics (e.g. capacitors and semiconductors), clean energy, aerospace, hypersonics, and space, which require specific novel and innovative materials.
Metalysis states that materials can be developed with specific physical properties and chemical compositions, which traditional manufacturing technologies may struggle with due to inherent limitations. This is particularly useful when looking to meet the demand of the high-entropy alloy (HEA) sector, as these alloys feature a different configuration of elements than traditional alloys.