Metalysis has secured a 1 million euro grant from the European Space Agency to transition its proprietary FFC Cambridge electrolysis process from batch to continuous production.

Metalysis has secured a 1 million euro grant from the European Space Agency to transition its proprietary FFC Cambridge electrolysis process from batch to continuous production. Based in South Yorkshire, the company aims to scale its solid-state titanium oxide reduction technology over a 24-month project timeline. This funding specifically targets the development of a quasi-continuous reactor configuration to increase output capacity for aerospace and industrial applications. The project focuses on producing high-purity titanium metal powders while reducing the energy intensity and hazardous waste associated with the traditional Kroll process.

The aerospace sector currently faces significant supply chain vulnerabilities, with China controlling approximately 70 percent of global titanium output following the disruption of Russian supply lines. Metalysis occupies a critical position in the materials value chain by offering an alternative to the multi-step, chlorine-dependent Kroll method. By bypassing traditional melting and thermomechanical processing, the FFC process enables more efficient production of metal powders suitable for powder metallurgy and near net shape manufacturing. This development directly addresses the urgent need for Western-based, sustainable titanium sources to support critical defense and space infrastructure.

Scaling the FFC process to a continuous operation is the primary technical hurdle for Metalysis to achieve commercial viability at bulk volumes. Success in this 24-month project will determine if the company can move beyond niche additive manufacturing applications to compete with established titanium sponge producers. Users and stakeholders should focus on the technical milestones of the reactor throughput and the resulting powder quality consistency compared to current industry standards.