Metalysis, an end-to-end manufacturer of solid-state metal and alloy powders, has installed three new Gen 1 research units – building on the capacity of the existing nine. This expansion of first stage research capabilities by a third was completed in response to unprecedented demand from advanced industries such as hypersonics, defense, clean energy (nuclear fission and fusion) and space.

Using the patented FFC Cambridge electrolysis process, Metalysis reduces metal oxides in the solid state. This method contrasts with traditional melting processes for alloy production, with the FFC Cambridge process scaled across Metalysis’ Gen 1 to Gen 4 units.

Each Gen 1 can produce grams of output per machine per run and is the first stage in the Metalysis product development process. The Gen 1s directly serve commercial clients’ advanced material development needs via producing low levels of output for proof of principle before the client’s requirements are elevated to Gen 2, then Gen 3, and potentially to Gen 4, which is capable of tens of tons of output per unit per year. The availability of different systems for trial batches offers flexibility to customers, negating the requirement to place large minimum order quantities.

New Gen 1 research units. Source: Metalysis

Each new unit contains a crucible of electrolyte (calcium chloride) and traditionally a carbon anode, with variations in the anode possible dependent upon the off-gas being produced. The metal oxide acts as the cathode, and with heating of the rock salt between 650° C to 950° C and a voltage applied, the oxygen is released, gravitating to the anode, leaving a metal sponge. This is then crushed, milled and dried, giving a metal or metal alloy powder. The process is agnostic to oxide composition, meaning the Gen units are not constrained by product type.

The benefits of the Metalysis electrolysis process are that in contrast to traditional melting processes for metal alloy powder production, electrolysis uses much lower temperatures and less energy and is a single-stage process rather than multi-stage, such as titanium alloy production. Also, no hazardous chemicals are used during the Metalysis process. This gives substantial energy and yield savings and means that sustainability is built-in across the Metalysis production process.

The Metalysis process in contrast to melting is also highly adaptable, so bespoke materials can be produced as directed by specific customer demand — the ability to create unique attributes in advanced materials has seen Metalysis emerge as a global partner to advanced manufacturing sectors that require specific novel and innovative materials. Materials can be developed with specific physical properties and chemical compositions, which traditional manufacturers struggle with due to inherent limitations in their production processes.

The expansion of the Gen 1s is directly due to increasing demand from new sectors: the high entropy alloy (HEA) sector and the growing commercial space sector. HEAs are a new class of alloy that ushers in a revolution in metallurgy not seen since the Bronze Age. Traditionally, alloys are metals alloyed to one base metal. HEAs are an equal configuration of elements, which means new alloys can be constructed with the attributes of each metal spread throughout the new alloy, such as strength, ductility and temperature resistance.