Metalysis Secures €1M ESA Funding to Scale Sustainable Titanium Production for 3D Printing

Metalysis, a UK-based manufacturer of critical metal and metal alloy powders, has secured nearly €1 million in funding from the European Space Agency (ESA) to develop a continuous or quasi-continuous sustainable process for titanium production using its patented Metalysis FFC Process.

Building a Western Titanium Supply Chain

The 24-month project will scale the FFC (Fray-Founders-Chen) process to support sustainable bulk titanium production. Currently, China supplies around 70% of Western aerospace titanium sponge, making this project critical for establishing a secure supply chain.

The consortium is led by Metalysis and includes UK companies Lucideon Ltd, TTP Plc, NCHG Ltd, and Austrian RHP-Technology GmbH.

Greener Than the Kroll Process

The Kroll process is the primary industrial method for producing titanium — a multi-step, energy-intensive approach that uses chlorine gas and produces hazardous waste. Metalysis claims its FFC solid-state electrolysis process offers several advantages:

• Minimises hazardous by-products
• Does away with multiple melting stages
• Enables direct production of titanium alloys in the solid-state
• Higher purity with lower energy consumption

Implications for Additive Manufacturing

Metalysis produces metal powders for industries including aerospace, space, defence, and clean energy. The company has been working with the ESA since 2019, most recently on projects to turn lunar regolith into inks and powder for 3D printing.

However, current production volumes are insufficient for the wider bulk titanium market. "The ability to scale production, in conjunction with employing appropriate powder metallurgy or additive manufacturing techniques, allows larger parts to be targeted, typically associated with more traditional fabrication routes," said Dr Ian Mellor, Managing Director at Metalysis.

Matthew Cook, Head of Space Exploration at the UK Space Agency, noted: "Titanium is essential for space exploration and satellite manufacturing, and establishing a secure, environmentally responsible supply chain is vital for the long-term competitiveness of our space sector."