Metalysis secures €1M ESA funding for titanium process
Metalysis Ltd, Rotherham, UK, has been awarded near €1 million in funding from the European Space Agency (ESA) to develop a continuous or quasi-continuous process for titanium production using its FFC (Fray-Farthing-Chen) molten salt electrolysis technology.
The twenty-four-month project aims to scale Metalysis’ FFC process to support more sustainable bulk titanium production and strengthen Western supply chains for critical metals.
Metalysis will lead a consortium including the UK’s Lucideon Ltd, TTP plc and NCHG Ltd, along with Austria’s RHP-Technology GmbH. Covering key unit operations associated with the FFC process, the partners bring experience in ceramics processing, materials science, electrochemistry, process development and Powder Metallurgy.
The consortium will work to scale the process beyond its current batch configuration towards continuous or quasi-continuous operation. According to Metalysis, its existing GEN-3 and GEN-4 reactors are able to produce titanium powders to the metal Additive Manufacturing sector, but production volumes are currently insufficient for wider bulk titanium markets.
Other consortium partners will contribute expertise in feedstock development, process scale-up, modelling and materials consolidation.
Titanium and its alloys are widely used in space and aerospace applications due to their high strength-to-weight ratio, corrosion resistance and performance at elevated temperatures. However, supply chain resilience has become an increasing concern.
Prior to 2022, a significant proportion of the titanium sponge used by Western aerospace manufacturers was sourced from Russia, Metalysis explains. China now accounts for roughly 70% of global titanium sponge production, increasing pressure to develop alternative supply routes.
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“The near €1 million from ESA to our consortium, led by Metalysis, reflects the strategic need across the space, aerospace, defence, hypersonics and wider advanced manufacturing sectors for industrial-scale production of critical metals such as titanium,” stated Nitesh Shah, CEO of Metalysis. “Scaling our technology to continuous or semi-continuous production will help strengthen Western supply of sustainable titanium, as the Metalysis FFC process is leaner, greener and cleaner than traditional manufacturing routes.”
The conventional Kroll process used for titanium production is energy-intensive and involves multiple processing stages, including melting and thermomechanical processing. The process also relies on chlorine gas and generates hazardous waste streams.
Metalysis stated that its FFC process offers a potential alternative through direct electrochemical reduction of metal oxides in molten salt. This approach enables titanium and titanium alloys to be produced in the solid state, avoiding several melting and thermomechanical processing steps associated with conventional production routes. The company also noted that combining the process with Powder Metallurgy routes could enable near-net-shape component production, potentially reducing material waste and energy consumption.
“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,” explained Matthew Cook, Head of Space Exploration at the UK Space Agency.
The FFC process was originally developed at the University of Cambridge in 1997 as a lower-cost and more energy-efficient route for producing titanium and other metals.
Tim Abbott, Director of Commerce at Lucideon, added, “By combining our materials and processing expertise with the facilities available at The AMRICC Centre, we aim to help develop scalable feedstock production processes that enable more efficient and sustainable manufacturing solutions.”
David Pooley, Project Leader at TTP plc, stated that the project represents “a major step towards securing a sustainable titanium supply chain for the UK and Europe,” noting that the company will apply modelling and pilot-scale data to support the transition to reliable large-scale production.
Erich Neubauer, General Manager at RHP-Technology, said the company will contribute its expertise in advanced materials and consolidation processes “to optimise titanium powder and bulk component properties.”
Nick Weeks, Director of NCHG Ltd, noted that the programme highlights the importance of developing more resilient and lower-impact supply chains for critical materials across UK and European industry.
