Metalysis
Metalysis is a UK-based advanced materials manufacturer that produces specialty metal and alloy powders (tantalum, aluminum-scandium, titanium, high entropy alloys) using its patented FFC Cambridge solid-state electrolysis process, serving aerospace, defense, semiconductor, clean energy, and space customers as a strategic Western alternative to Chinese supply chains.
- Company typePrivate
- Founded2005
- HeadquartersRotherham, United Kingdom
- Headcount11–50
- GTM typeB2B
- OfferingHardware or Manufacturing
What Metalysis does
Metalysis is a UK-based advanced materials manufacturer that produces metal and alloy powders using its patented FFC Cambridge solid-state electrolysis process. The proprietary technology reduces metal oxides directly into pure metals and alloys at 650-950°C via molten salt electrolysis, bypassing the energy-intensive Kroll process used for titanium and overcoming limitations of traditional melting methods for alloy combinations with disparate melting points. Applicable to 49 elements of the periodic table and protected by over 300 patents, the FFC process enables production of novel alloys that cannot be made by conventional means, including high-scandium aluminum alloys (Al3Sc with up to 36wt% scandium loading), high entropy alloys with five or more equally balanced metals, and refractory compositions for extreme environments.
The company's product portfolio includes tantalum powders for capacitors and semiconductors, aluminum-scandium master alloys for 5G BAW filters and aerospace structural components, high entropy alloys for hypersonics and nuclear applications, and titanium/titanium-aluminide powders for additive manufacturing. A four-generation reactor platform scales output from gram-level R&D (Gen 1) through kilogram demonstration (Gen 2) and tonne-scale commercial production (Gen 3) to tens-of-tonnes industrial capacity (Gen 4). Metalysis acquired a 40 kW Tekna spheroidiser in late 2024 to produce spherical powders suitable for additive manufacturing.
Metalysis operates a direct B2B sales model targeting aerospace, defense, semiconductors, clean energy, medical, and space sectors via bespoke quotations with customization across particle size, purity, morphology, and chemical composition. Revenue streams span metal powder sales, contract analytical testing and R&D services, and government/ESA-funded technology development partnerships. The company has strategic relationships with the European Space Agency (selected as the technology platform for all ESA oxygen extraction projects since 2019), the UK Space Agency, Skyrora for rocket engine alloys, and a consortium of UK and European partners for titanium scaling. With operations concentrated at two Rotherham sites and ~50 employees, Metalysis positions itself as a critical Western midstream alternative to Chinese and Russian dominance in critical mineral processing for national security applications.
Metalysis firmographics
Firmographics- Name
- Metalysis
- Legal name
- Metalysis Ltd
- Website
- https://metalysis.com
- Company type
- Private
- Founded year
- 2005
- Operating status
- Operating
- Headcount range
- 11–50 employees
- Short description
- Metalysis is a UK-based advanced materials manufacturer that produces specialty metal and alloy powders (tantalum, aluminum-scandium, titanium, high entropy alloys) using its patented FFC Cambridge solid-state electrolysis process, serving aerospace, defense, semiconductor, clean energy, and space customers as a strategic Western alternative to Chinese supply chains.
- Ownership category
- akta.pro rank
Metalysis industry classification
Industry- Product category
- Specialty Metal Powders
- NAICS
- Primary Metal Manufacturing (331), Nonferrous Metal (except Aluminum) Smelting and Refining (331410), Powder Metallurgy Part Manufacturing (332117)
- SIC
- Primary Smelting & Refining Of Nonferrous Metals (3330)
- akta.pro primary industry
- Metal Powders (LPBF/DMLS/EBM) (IMAAABAE)
- akta.pro secondary industries
- Aluminum Casting & Ingot/Billet/Slab Production (IMAKACAE), Precious Metals Smelting & Refining (IMAKAEAE)
Keywords
Where Metalysis is headquartered
LocationHeadquarters
- HQ city
- Rotherham
- HQ country
- United Kingdom
- HQ region
- Europe
Offices2 records
Markets served
Metalysis business model
Business model- GTM type
- B2B
- Offering type
- Hardware or Manufacturing
- Cost components
- Technology or R&D, Personnel, Operations, Supply Chain, Infrastructure
Revenue model
- Metal Powder and Alloy Sales: Primary revenue from selling metal powders (tantalum, aluminum-scandium, titanium, high entropy alloys) and alloy powders produced via the FFC process. Products sold include standard stock items and bespoke orders tailored to customer specifications for particle size, morphology, purity, and chemical composition.
- Research and Development Services: Commercial R&D services provided to global clients, including analytical testing services (chemical and physical characterization of metal powders, metal oxides, molten salts) and bespoke consultancy to help customers overcome laboratory challenges. The company also conducts contract analysis for the metals and related industries.
- Technology Development Partnerships: Revenue from ESA and government-funded technology development programs. The €1M ESA titanium production project and ESA Skyrora propulsion alloy development represent consortium-led development work where Metalysis leads or participates in advancing its core technology for specific applications.
Pricing tiers
| Model | Billing | Price |
|---|---|---|
| Other | Multi-year contract | Bespoke quotations for metal and alloy powders |
Go-to-market motion1 record
Distribution channels1 record
Marketing channels4 records
Metalysis product offering
Product offeringCore offering
Metalysis manufactures and sells specialty metal and alloy powders produced via its patented FFC Cambridge solid-state electrolytic process. The company produces tantalum, aluminum-scandium, titanium, titanium-aluminide, and high entropy alloy powders from gram to tens-of-tonnes scale for aerospace, defense, semiconductor, clean energy, space, and medical device customers. It also provides contract analytical testing and R&D services.
Product overview
Metalysis is an end-to-end manufacturer of solid-state metal and alloy powders deploying its patented FFC Cambridge electrolysis process. The company's portfolio includes Tantalum powders (capacitor grade, AM grade), Aluminum-Scandium (Al₃Sc) master alloys with up to 36 wt% scandium, High Entropy Alloys (5-6 metal compositions), and Titanium/Titanium-Aluminide alloys. Products scale from gram-level (Gen 1 R&D) through kilogram demonstration (Gen 2), tonne-scale commercial (Gen 3), to tens-of-tonnes industrial production (Gen 4). The company also offers analytical testing and R&D services. Core technology enables production of metals from 49 periodic table elements, with in-house spheroidisation for spherical powder production.
Differentiator
Problem solved
Functional benefit
Products and services
- Tantalum Powders & Alloys High-purity tantalum metal powders in various particle sizes and purities, used for capacitors in smartphones, computers, IoT and automotive electronics; additive manufacturing feedstock; semiconductors; and chemical plant equipment.
- Aluminum-Scandium (Al3Sc) Alloy Scandium tri-aluminide master alloy with up to 36 wt% (25 atom%) scandium loading in fully homogenized form, used in semiconductor sputtering targets for thin film deposition, AlScN coatings, Bulk Acoustic Wave (BAW) filters for 5G, and aerospace structural components.
- High Entropy Alloys (HEAs) Advanced multi-metal alloys (typically 5+ elements in equal configuration) with superior properties for aerospace, extreme environments, and refractory applications; suitable for nuclear, hypersonics, and consumer tech uses.
- Titanium & Titanium Alloys Titanium metal and alloy powders including Ti-6Al-4V (Grade 5) and gamma Titanium-Aluminide intermetallics, supplied for additive manufacturing, aerospace structural parts, jet engines, medical implants, and space applications.
- Analytical & R&D Services Contract analytical testing, method development, and bespoke consultancy for chemical and physical characterization of metal powders, metal oxides, molten salts, and refining processes, serving global clients in the metals and related industries.
Quantifiable outcome
- 50% more energy-efficient than traditional titanium production processes
- +5 more outcomes
Companies that use Metalysis
Customer profileNamed customers5 records
Segments4 records
Ideal customer profiles4 records
Metalysis technology and API
TechnologyTechnology focussed Yes
API detail
- Has API
- No
- API docs
- API detail
Core technology
AI maturity
App detail
Feature6 records
Metalysis partnerships and signals
Strategic signalPartnerships
Ten partnerships are on record, tiered core and supporting.
- European Space Agency (ESA)coreESA has partnered with Metalysis since 2019 on lunar oxygen extraction. Metalysis was selected as the technology platform for all ESA oxygen extraction projects. Current €1M 24-month project to develop continuous titanium production for space and aerospace applications. ESA is actively supporting development of sustainable, economically viable, and secure titanium production routes.
- Gas Recovery and Recycle Limited (GR2L)supportingUK clean tech firm contracted to install ArgonØ™ argon recycling system at Metalysis facilities. System recovers, purifies, and recycles exhaust purge argon gas from industrial processes. Strategic expansion for GR2L beyond traditional markets (solar photovoltaics, microelectronics) into advanced manufacturing and materials processing sectors.
- SkyroracoreUK rocket company selected Metalysis to develop Tanbium refractory alloy powder for rocket engine components (nozzles and combustion chambers) under ESA-funded program. Phase one runs 9 months focusing on material production and additive manufacturing testing. Metalysis produces the novel alloy while Skyrora demonstrates in components using Skyprint 2 additive manufacturing system.
- UK Space AgencycoreUK Space Agency co-funds lunar regolith processing projects with Metalysis. Partnered since 2019 on oxygen extraction from lunar rock, with ongoing collaboration to deploy larger scale units (Gen 2 and above) on the lunar surface.
- Thermo-Calc Solutions ABsupportingComputational materials design partner for Skyrora project. Designed Tanbium alloy using Integrated Computational Materials Engineering (ICME) to optimize composition for high-temperature strength, improved ductility, enhanced oxidation resistance, and better laser processability.
- Lucideon LtdsupportingUK consortium partner in ESA titanium production project. Contributes expertise in ceramics processing and materials science. Leverages AMRICC Centre facilities to develop and optimize scalable feedstock production processes for Metalysis FFC technology.
- TTP PlcsupportingUK consortium partner in ESA titanium production project. Contributes expertise in electrochemistry, process development, and translating cutting-edge electrochemistry into robust, scalable manufacturing solutions using advanced modeling and pilot-scale data.
- NCHG LtdsupportingUK consortium partner in ESA titanium production project. Contributes expertise in powder metallurgy and commitment to building resilient, lower-impact supply chains for British industry based on reduce, re-use, and recycle principles.
- RHP-Technology GmbHsupportingAustrian consortium partner in ESA titanium production project. Contributes extensive know-how in materials consolidation to optimize titanium powder and bulk component properties. Also partnered on SPS and hot pressing trials for aluminum scandium alloy discs.
- Danish Technological InstitutesupportingLead partner in Danish-led ESA-backed research project to convert lunar regolith into conductive inks and powders for printing electronics on the Moon. Metalysis contributes electrochemical processing to extract oxygen and repurpose metal-rich residues as functional materials for additive manufacturing.
Scale indicators10 records
Recent moves10 records
Expansion highlights6 records
Metalysis competitors and assessment
Company assessmentDirect peers
- AP&C (GE Aerospace): Owned by GE Aerospace, AP&C is a leading manufacturer of premium titanium and other metal powders for additive manufacturing using plasma atomisation. Directly comparable to Metalysis as a specialty metal powder supplier into aerospace and medical AM.
- 6K Additive: 6K Additive produces premium metal powders for additive manufacturing using a proprietary sustainable process. Competes with Metalysis in titanium and refractory alloy powders for aerospace and defence AM applications.
- Tekna: Tekna manufactures spherical metal powders via plasma atomisation, including refractory and titanium alloys. Metalysis acquired a Tekna spheroidiser to produce spherical powders, and Tekna is a direct competitor in the same metal powder for AM category.
Broad incumbents
- Carpenter Technology Corporation: Specialty alloy producer with deep aerospace/defense customer relationships and titanium powder portfolio. Overlaps with Metalysis in titanium and high-performance alloys but operates as a broad incumbent across many alloy families.
- Sandvik Additive Manufacturing: Sandvik's additive manufacturing division produces gas-atomised metal powders (including titanium and refractory alloys) for industrial AM. Comparable to Metalysis as a specialty powder supplier, but within a much larger diversified industrial group.
- Heraeus: German precious metals and technology group with metal powder and refractory alloy capabilities serving electronics, aerospace, and industrial customers. Comparable to Metalysis in refractory/precious metal powders and high-end specialty alloys.
- Höganäs AB: World's largest producer of metal powders, predominantly iron and steel-based, with growing specialty and AM-grade offerings. Overlaps with Metalysis in metal powder manufacturing for additive manufacturing and powder metallurgy.
- Constellium: Global specialty aluminium products manufacturer supplying aerospace, packaging, and automotive markets. Comparable to Metalysis in supplying high-performance aluminium-based products to aerospace and defence, though at far larger scale and broader portfolio.
Regional players
- Iluka Resources: Australian critical minerals mining and refining company that led Metalysis's 2016 funding round. Comparable as a midstream Western critical minerals competitor (rare earths/refractory metals), though geographically focused on Australian feedstock rather than UK manufacturing.
Emerging players
- Phased Array / Equispheres: Equispheres is an emerging Canadian metal powder producer focused on high-flow aluminium powders for binder jetting and AM. Comparable to Metalysis as a specialty AM powder innovator, though more narrowly focused on aluminium.
Market position
Strengths4 records
Weaknesses4 records
Competitive moat5 records
Key risks5 records
Key highlights6 records
Customer concentration
Metalysis social profiles
Digital presenceMetalysis compliance and trust
Trust signalCompliance2 records
Metalysis financial estimates
Financial estimateRevenue estimate
Valuation estimate
Metalysis leadership team
Management profileNumber of profiles
Profiles10 records
Metalysis funding detail
Funding detailFunding overview
Funding rounds8 records
Investors11 records
Funding detail is available on the Subscription and Enterprise plan.Contact sales →
Metalysis M&A and investment
M&A and investmentM&A
Investments
M&A and investment is available on the Subscription and Enterprise plan.Contact sales →
Frequently asked questions about Metalysis
What does Metalysis do?
Metalysis manufactures and sells specialty metal and alloy powders produced via its patented FFC Cambridge solid-state electrolytic process. The company produces tantalum, aluminum-scandium, titanium, titanium-aluminide, and high entropy alloy powders from gram to tens-of-tonnes scale for aerospace, defense, semiconductor, clean energy, space, and medical device customers. It also provides contract analytical testing and R&D services.
Is Metalysis a public or private company?
Metalysis is a private company. It is classified as venture growth investor backed and is currently operating.
When was Metalysis founded?
Metalysis was founded in 2005. It employs 11 to 50 people.
Where is Metalysis based?
Metalysis is headquartered in Rotherham, United Kingdom, in the Europe region.
How does Metalysis make money?
Three revenue lines are on record. Metal Powder and Alloy Sales are the primary driver. The others are research and Development Services and technology Development Partnerships.
Who are Metalysis's main competitors?
Direct peers on record are AP&C (GE Aerospace), 6K Additive and Tekna. Broad incumbents are Carpenter Technology Corporation, Sandvik Additive Manufacturing, Heraeus, Höganäs AB and Constellium. Iluka Resources is listed as a regional player. Phased Array / Equispheres is listed as an emerging player.
Does Metalysis have an API?
No public API is recorded for Metalysis.
What industry is Metalysis in?
Metalysis's product category is Specialty Metal Powders. Its primary akta.pro industry code is IMAAABAE, Metal Powders (LPBF/DMLS/EBM), with a secondary code of IMAKACAE, Aluminum Casting & Ingot/Billet/Slab Production. Its NAICS code is 331 and its SIC code is 3330.