News: Metalysis achieves commercial specification of space alloy

Metalysis, the Rotherham-based end-to-end manufacturer of solid-state metal and alloy powders, and global leader in materials science, has produced C-103 alloy powder for high-demand markets such as defence, medical, semiconductor and energy.

The company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. With a Materials Discovery Centre on the Advanced Manufacturing Park (AMP) in Rotherham it also operates a site at Manvers.

The current C-103 market is estimated at $46m, reaching $200m by 2032 as users search for alternative, secure and consistent supply of this high-performance refractory alloy for use within their high temperature and extreme environment applications.

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.

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The Metalysis process in contrast to melting is also highly adaptable, so bespoke materials can be produced as directed by specific customer demand.

C-103 alloy is one of the most widely used niobium alloys. Niobium’s melting point of 2477 degrees Celsius, excellent corrosion resistance and high strength to weight ratio ensures it is a metal of choice for critical sectors.

C-103 faces supply chain vulnerability primarily because of shortages in Hafnium metal (as opposed to hafnium oxide) production, as competing demand from other hafnium compounds has increased, driven by the rapid expansion of semiconductor chip manufacturing.

Demand is also set to increase also following recent advances in additive manufacturing (AM - 3D printing). The ability to manufacture complex C-103 structures and geometries with minimal material waste addresses one of the historical manufacturing challenges pertaining to C-103, reducing costs and lead times.

Nitesh Shah, CEO of Metalysis, said: "Metalysis is adding C-103 niobium hafnium titanium alloy to its product suite given our core focus on refractory alloys – combined with lightweighting expertise. C-103 was developed in the 1960s but now we are seeing a huge surge in demand because of the renewed race for space – as well as advanced manufacturing sectors such as hypersonics / defence.

"The Metalysis FFC process is able to produce C-103 alloy to the morphology required by AM partners – whilst reducing metal oxides rather than metal means we are not constrained by the availability of hafnium metal. Our engagement with customers in this sector has already been highly encouraging.”

In March Metalysis secured nearly €1m via the European Space Agency (ESA) to scale sustainable titanium production. Titanium is a critical metal for space and aerospace applications, and ESA is actively supporting the development of a more sustainable, economically viable, and secure production route. The two year project has both space and non-space applications, and builds on Metalysis’ proccess.

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News: Metalysis doubles Gen 2 R&D demonstration units

Metalysis, the end-to-end manufacturer of solid-state metal and alloy powders and global leader in materials science, is increasing its output of specialist metals amid growing pressure to reduce reliance on Chinese supply chains.

With a Materials Discovery Centre on the Advanced Manufacturing Park (AMP) in Rotherham, the company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits.

Earlier this year, Rothbiz reported on the increasing in Gen 1 research units, which can produce grammes of output per machine per run. Metalysis has now doubled its Gen 2 units which enable transition from grams to kilograms-scale output.

The move is to meet unprecedented demand from advanced industries, including electronics, hypersonics, defence, clean energy and space. This expansion supports customers developing next-generation materials and reflects heightened urgency to secure non-Chinese midstream processing options following ongoing uncertainties surrounding new Chinese export controls on critical minerals and rare earth elements, first enacted in April.

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Nitesh Shah, CEO of Metalysis, said: “We are delighted to be doubling our Gen 2 units, just seven months after we increased our Gen 1 capacity by 1/3. We are seeing increasing demand for our products at the Gen 2 level, sending material to clients for evaluation and qualification into specialist markets, with particular interest from sputtering target manufacturers.

"A range of advanced manufacturing sectors come to Metalysis because of our core suite of products - capacitor grade tantalum, scandium tri-aluminide (Al3Sc), niobium alloys and our ability to create lightweight refractory high entropy alloys, and because clients know that with all the materials that we produce we bring unique and bespoke physical and chemical attributes to the end-material, meaning we are without competition across a range of products."

China continues to dominate mining and midstream processing, with 90 per cent of global midstream capacity. To reduce this dependency, Western nations are urgently seeking alternative processing solutions. Metalysis is well-positioned to fill this gap, offering scalable midstream capability across a wide range of critical materials.

Shah added: "The recent REE controls by the Chinese have accelerated this process as clients require metal feedstocks and midstream processing from outside of China, and this will be the dominant trend across critical materials over the next few years."

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News: Metalysis increases Gen 1 research units by one third

Metalysis, the end-to-end manufacturer of solid-state metal and alloy powders and global leader in materials science, today announced the installation of three new Gen 1 research units - building on the capacity of the existing nine - so expanding Metalysis' first stage research capabilities by a third - in response to unprecedented demand from advanced industries such as hypersonics, defence, clean energy (nuclear fission and fusion) and space.

The company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. With a Materials Discovery Centre on the Advanced Manufacturing Park (AMP) in Rotherham it also operates a site at Manvers.

Each Gen 1 can produce grammes 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 tonnes of output per unit per year. The availability of different Gen’s for trial batches offers flexibility to customers, negating the requirement to place large minimum order quantities.

Each Gen unit contains a crucible of electrolyte (calcium chloride, more commonly known as rock salt) 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 650-950 degrees Celsius 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.

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Demand is coming from the high entropy alloy sector and the growing commercial space sector.

High-entropy alloys (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 – e.g, strength, ductility, fatigue, and corrosion, oxidation, and temperature resistance.

Nitesh Shah, CEO of Metalysis, said: “We are delighted to be expanding Metalysis’ development capabilities by increasing the number of our Gen 1 units by a third. This need for substantial expansion is led by our partners and potential partners – particularly in the hypersonics and space sectors – who have sourced Metalysis as their global partner for the development and commercial supply of advanced novel materials. As these innovative sectors grow, the need for novel advanced materials increases, and our Gen 1 units will allow us to work with partners on the required physical properties and chemical compositions of their advanced materials.

"Metalysis recently purchased a spheroidiser for in-house production of spherical powders and this expansion of our Gen 1s further expands our in-house capacity."

Rawmarsh and Consibrough MP John Healey recently visited Metalysis’ manufacturing centre in Wath. He said: "The company has an important part to play in the country’s critical metals sector through its production of metallic and intermetallic powders and alloys that can be used in a range of different products and sectors.

“I’m looking forward to hearing more about the company’s success in the future as it continues to expand in the years to come.”

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News: Metalysis continue to aid hunt for oxygen on the Moon

Rotherham-based tech firm, Metalysis, is taking part in more out of this world research projects.

The Advanced Manufacturing Park (AMP) company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. It is commercialising the technology to produce titanium, tantalum, and related high value alloys.

Selected by the European Space Agency (ESA), Thales Alenia Space is leading a €1m study to develop a demonstration payload to extract oxygen from Moon rock to sustain human activities on the Lunar surface.

For a sustainable habitation on the Moon, humans will need to utilise resources that they find on the Moon rather than transport these resources from Earth; one of these resources is oxygen.

Last year Metalysis successfully extracted oxygen from replicated moonrock (lunar regolith) which predominantly contains aluminium, silicon, and oxygen, as part of the research programme. The metal powder by-product collected during the process is also generating huge interest.

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Andrew Stanniland, CEO of Thales Alenia Space in the UK, said: "This contract award is incredibly exciting. The adaption of processes and tools to the space environment, many of which we take for granted on Earth, will be critical in many areas of our future. I am proud that our dedicated teams will be leading this study together with our valued partners AVS, Metalysis, Open University and Redwire Space Europe to solve the complex challenge of creating oxygen to sustain life on the lunar surface."

Metalysis has also been named in a project backed with £218,000 from the UK Space Agency.

Called "Developing In Situ Resource Utilisation Production Technology (DISRUPT)," the project will establish an end-to-end demonstration capability in the UK which would contribute significantly to the de-risking of technology used for In Situ Resource Utilisation (ISRU). This end-to-end demonstration capability would allow many of the uncertainties present in the process chain to be understood and characterised; especially the effect of the regolith (Moon soil) collection and pre-processing of the feedstock for the Metalysis-FFC process reactor. This activity will be conducted in partnership with Metalysis, AVS, URA Thrusters and the Open University.

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News: Metalysis make giant leap toward extracting oxygen from moonrock

Scientists at Rotherham-based tech firm, Metalysis, are over the moon after making ground-breaking developments that could shape the future of space exploration.

The Advanced Manufacturing Park (AMP) company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. It is commercialising the technology to produce titanium, tantalum, and related high value alloys.

Rothbiz reported last year that innovative technology pioneered by Metalysis is being backed by the European Space Agency (ESA) in their efforts to "mine space" and colonise the Moon.

The firm has now successfully extracted oxygen from replicated moonrock (lunar regolith) which predominantly contains aluminium, silicon, and oxygen, as part of the research programme. The metal powder by-product collected during the process is also generating huge interest.

The project is providing an assessment to prepare and de-risk technology developments, focussed towards oxygen production for propellants and life support consumables. The ability to extract oxygen on the moon is vital for future exploration and habitation, being essential for sustainable long duration activities in space. In-Situ Resource Utilisation (ISRU) will significantly reduce the payload mass that would be needed to be launched from earth. On a space journey to Mars for example, the extraction of oxygen could see a refuelling station on the Moon.

The research, which was conducted by Metalysis using patented processes, has produced a multi- kilogram batch of metal powder from the lunar regolith, opening possibilities to make products to scale, rather than just acquiring samples. This is the first time the metal powder by-product has been produced in these quantities, sparking much interest from customers, and other interested parties, to carry out their own testing and further research. Since the material is in powder form, it is ideal to be used in techniques such as Additive Manufacturing (AM), both for space infrastructure development and in-situ equipment manufacturing.

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Learning surrounding the extracted metal powders is also applicable to the on-earth manufacture of products, which could be used in a range of fast-growing applications including medical prosthesis, vehicle, and aviation lightweighting, electronics, magnetic materials, as well as space exploration.

Metalysis, which has both research and production facilities based in Rotherham, has doubled in size in recent months and already has a global reach. The company, which was born over 15 years ago, has gone from strength to strength in recent years, driving forward initiatives such as this research programme, funded by themselves, as well as other privately and publicly sponsored projects looking to advance the potential of metal powders both on earth and in space.

Ian Mellor, managing director at Metalysis, said: "We are excited to be at the forefront of this In-Situ Resource Utilisation activity, demonstrating multiple kilogram batches of metal alloy powder can be produced from moon rock, using the Metalysis technology. This enables new design opportunities in the construction of lunar habitats, which until now could only be envisaged conceptionally.”

Metalysis is funded by the UK Space Agency through the European Space Agency.

Sue Horne, Head of Space Exploration at the UK Space Agency, said: “The UK is playing a leading role in space exploration, including the Rosalind Franklin rover which launches next year to search for signs of life on Mars.

“Finding ways to create the things we need to support life - food, water and breathable air – will be essential for longer-term crewed missions into deep space. This exciting research from Metalysis brings us a step closer to making that possible.”

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News: Metalysis to aid hunt for oxygen on the Moon

Innovative technology pioneered in Rotherham by Metalysis is being backed by the European Space Agency (ESA) in their efforts to "mine space" and colonise the Moon.

The Advanced Manufacturing Park (AMP) company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. It is in the process of commercialising the technology to produce titanium, tantalum, and related high value alloys. These are used increasingly by major worldwide industries such as aerospace, marine, medical, chemical, automotive and electronics.

As ESA and other agencies prepare to send humans back to the Moon – this time to stay – technologies that make use of materials available in space are seen as key to sustainability, and a stepping stone in humankind's adventure to Mars and farther into the Solar System.

As reported by Rothbiz in 2017, Metalysis has been working with the agency to see if any of the "raw materials" on the Moon which have the potential to be mined can be converted into usable materials using the firm's electrochemical process.

The Metalysis process has recently been proven for the industrial-scale production of metals and alloys, leading to the present investigation into the potential application of this process to regolith-like materials in a lunar context. An initial proof of concept study has resulted in a metallic powder where 96% of the total oxygen is successfully extracted, in conjunction with giving a mixed metal alloy product that can be used for in-situ manufacturing.

The project will provide an assessment to prepare and de-risk technology developments, focussed towards oxygen production for propellants and life support consumables. The ability to extract oxygen on the moon is vital for future exploration and habitation, being essential for sustainable long duration activities in space. In-Situ Resource Utilisation (ISRU) will significantly reduce the payload mass that would be needed to be launched from earth.

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A previous NASA-funded study, undertaken in 2004, investigated the applicability of the FFCCambridge process for the electrolysis of lunar ilmenite, termed the Ilmenox process. At the time of this previous work, the development of the FFC-Cambridge process was still in its early stages and had only been proven at a laboratory scale.

Since this time, Metalysis has successfully scaled-up its technology, with a further three generations designed, commissioned, and in operation. As of 2018, titanium and tantalum metal production has been developed at an industrial scale, and the production of many other metals and alloys has also been proven. More recently, the production of intermetallics of aluminium and scandium has been increased to industrial scale.

Two SME teams have been working to devise process-monitoring systems that will work with the Metalysis electrochemical cells in space.

Working alongside Metalysis, Added Value Solutions (AVS) will work to determine the steps required to translate the Metalysis technology from an on-earth to extra-terrestrial environment.

Ian Mellor, managing director at Metalysis, said: "We are really pleased Metalysis is involved in this exciting programme; taking an established earth-based technology and applying it to a lunar setting. The fact that the process is capable of simultaneously producing both oxygen and metal powders is unique, offering potential solutions to two key areas of the ESA Space Resources Strategy."

Sue Horne, Head of Space Exploration at the UK Space Agency, added: "In the future, if we want to travel extensively in space and set up bases on the Moon and Mars, then we will need to make or find the things required to support life - food, water and breathable air.

"The involvement of Metalysis in a programme that aims to do just that, by producing oxygen on a lunar setting, will showcase the UK's space credentials on the world-stage and help unlock breakthroughs that bring future space exploration a step closer."

The UK Space Agency, NASA and other partners recently signed a historic agreement on principles for space ahead of a future mission to the Moon.

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News: Details of Metalysis administration revealed

The results of the administration of Metalysis Ltd, the innovative Rotherham-based company, included 47 redundancies and around £8m owed to creditors, on top of the millions secured over the years from investors who are unlikely to now see a return.

The game-changing technology and multi-million pound Rotherham facilities are now owned by a Maltese-headquartered mining group.

The Manvers company held the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. With a Materials Discovery Centre on the Advanced Manufacturing Park (AMP), also in Rotherham, the firm raised millions for research and to build towards commercial production.

Administrators were brought in after the firm, which employed 60 staff, experienced financial difficulties predominantly due to an extended recent investment round. Metalysis was acquired last month by Power Resources Group, a metallic materials science company which operates in Rwanda and Macedonia.

Metalysis was pre-revenue and had recently successfully got up to industrial scale with its fourth generation plant (Gen4), creating tonnes of high value metals.

Documents filed by joint administrators Eddie Williams and Chris Petts of Grant Thornton UK LLP show that the terms of a loan from US venture capital firm, Hercules, and pressure from HMRC regarding tax arrears, led to bosses of the Cambridge University spinout seeking buyers and eventually placing the business into administration.

The documents state: "In order to reach the stage were the technology could be fully commercialised, the directors actively sought to raise further equity, of c£15m. The business plan was to utilise these proceeds to continue research and development, or possible production of further Gen4 machines, which in turn would generate revenue. The plan was for the business to be breakeven within three years.

"This fundraising continued for 12 months prior to the company's administration, but was not successful for a number of reasons."

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Existing investors, which included Woodford Investment Management and Australian minerals firm, Iluka Resources Limited, were no longer in a position to invest and problems were incurred over the complex share structure, the complex technology and that much of the funding was for working capital.

A 2018 fundraising of £12m included a $7.5m loan from Hercules Capital which included a covenant that stated that the business must maintain liquidity of at least $2.5m at all times. With cash running out and fund raising unlikely, employees agreed to work a four day week but by April the covenant was breached and discussions over a possible sale and administration began.

Two indicative offers were received in May, but due to short timescales, they did not progress. The documents also show that the Government was approached over providing breaching funds, but they were unable to do so.

With administrators appointed in June, the business continued to trade whilst a buyer was found. Indeed, turning off the Gen4 machine may have led to significant costs in restarting it.

No interested parties offered any working capital and so 37 redundancies were made on June 14. 49 redundancies were made in total.

Of the two indicative offers, the higher did not progress and four further offers for the business and assets were received. Working quickly, the bid from Power Resources Group was accepted and the $2.5m deal included the transfer of ten employees.

the successful bid was assessed to offer the best result for the creditors, notably Hercules Capital who stand to get $2m of their $3.7m debt as a secured creditor. Money owed to unsecured creditors stands at £5.8m.

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News: Rotherham-based Metalysis acquired

Metalysis ltd, an innovative Rotherham-based company that has secured millions from investors in recent years, has been acquired having called in administrators following financial difficulties.

The Manvers company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. With a Materials Discovery Centre on the Advanced Manufacturing Park (AMP), also in Rotherham, the firm raised a further £12m last year ahead of the start of commercial production.

Power Resources Group, a metallic materials science company which operates in Rwanda and Macedonia, has announced that it has acquired Metalysis.

A registration of a charge relating to the acquisition and asset sale agreement has been lodged with Companies House.

Employing 60 people from its two sites, Metalysis appointed Eddie Williams and Chris Petts of Grant Thornton UK LLP as joint administrators at the start of June.

The pair stated that Metalysis had experienced financial difficulties predominantly due to an extended recent investment round and needed to secure immediate investment.

It has previously been reported that a number of redundancies were made by the administrators.

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In a post on social media, Ray Power, CEO of Power Resources Group, said that he was "delighted to expand the Power Resources Group family with the acquisition of a great company and great team at Metalysis."

Power Resources Group operates mines in Rwanda, one of the world's largest producers of tin, tantalum, and tungsten. It opened a tantalum processing plant in Macedonia in 2018.

Metalysis' process, developed through years of R&D, takes the tantalum oxide feedstock and transforms it directly into tantalum powder using electrolysis. The process uses less energy than traditional processes as it does not require the melting of metals, and the salt used in producing the metals can be recycled.

Tantalum powders are used in the production of electronic components.

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News: Metalysis in administration

Metalysis ltd, an innovative Rotherham-based company that has secured millions from investors in recent years, is looking for a buyer having called in administrators following financial difficulties.

The Manvers company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. With a Materials Discovery Centre on the Advanced Manufacturing Park (AMP), also in Rotherham, the firm raised a further £12m last year ahead of the start of commercial production.

Commercial production began in September and marked the technology's ascension from a Cambridge University breakthrough, through more than a decade of development, to offering industrial scale production of demand driven, high value powder alloys for international aerospace, automotive, additive and advanced manufacturing applications.

It employs 60 people from its two sites.

Now Eddie Williams and Chris Petts of Grant Thornton UK LLP have been appointed joint administrators.

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The firm said that Metalysis has experienced financial difficulties predominantly due to an extended recent investment round. As a result of urgent liquidity issues the directors had no alternative other than to place the business into administration.

Eddie Williams, advisory partner at Grant Thornton UK LLP said: "Metalysis is a truly innovative UK business with a unique disruptive technology that urgently requires new ownership and further ongoing investment. Despite the directors' best efforts and significant global interest, the business could not continue to operate without the protection of administration.

"Our immediate priority and urgent focus is to work alongside a credible interested party to secure immediate investment as part of a sale process and we would encourage any parties with interest to contact the administrators. With that support, I would hope that the business can continue to operate and thrive."

Having successfully got up to industrial scale with its fourth generation plant (Gen4), work is underway on "Generation 5" - manufacturing options for thousands of tonnes per annum of high value metal alloy powders. It is designed to retrofit into an existing industrial site.

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News: MoD becomes Metalysis customer

Metalysis has secured a deal with the Ministry of Defence (MOD), to supply titanium powder through the Materials for Strategic Advantage research programme.

The Manvers company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. It is in the process of commercialising the technology to produce titanium, tantalum, and related high value alloys. These are used increasingly by major worldwide industries such as aerospace, marine, medical, chemical, automotive and electronics.

The order is the first that Metalysis has announced from its industrial plant, known as Gen4, housed within its Materials Manufacturing Centre in Rotherham.

Gen4 recently commenced commercial production at Manvers. It is the first facility of its kind in the world.

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The MoD's Defence Science and Technology Laboratory (Dstl) provides UK Government with sensitive and specialist research, advice, analysis, technical and systems risk management and assurance. Based in Porton Down it has already revolutionised the production of titanium by reducing the 40 stage process down to just two steps and potentially halving the cost. It is based on the FASTForge project being carried out at the University of Sheffield which relies on Metalysis technology.

Dr Dion Vaughan, CEO at Metalysis, said: "Naturally, we are pleased to welcome Dstl as the first announced customer from our newly operating industrial plant.

"Commencing production from Gen4 marked a positive outcome following years of technological development. Dstl is a global leader in recognising and supporting scientific breakthroughs, and an ideal customer for Metalysis.

"We look forward to continuing to work together. Separately, we anticipate reporting positive outcomes from other customer discussions in coming months."

Backed by investors and grants the Cambridge University spin out has secured over £30m of investment and opened a Materials Discovery Centre in a 22,000 sq ft unit on the Advanced Manufacturing Park (AMP), also in Rotherham.

At Manvers, Metalysis has successfully produced both of its intended Gen4 launch products - titanium family alloys and an aluminium-scandium master alloy.

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News: Metalysis a prime example of the strength and economic potential of the North

Innovative Rotherham firm, Metalysis recently hosted a delegation led by MP Richard Harrington – Business and Industry Minister – as it celebrated becoming a Northern Powerhouse Partner.

The Manvers company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. With a Materials Discovery Centre on the Advanced Manufacturing Park (AMP), also in Rotherham, the firm raised a further £12m earlier this year ahead of the start of commercial production.

The Northern Powerhouse Partners Programme is a network of leading companies who all believe strongly in the economic potential of the North, and support the need for a combined effort by government and business to realise that potential.

Commercial production in September marked the technology's ascension from a Cambridge University breakthrough, through more than a decade of development, to offering industrial scale production of demand driven, high value powder alloys for international aerospace, automotive, additive and advanced manufacturing applications.

More broadly, the Partners Programme's ethos encapsulates Metalysis' clear and continued commitment to growing the business in the North of the UK, and using its technology to provide a nationally significant capability for global metal powder supply chain activity.

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Dr Dion Vaughan, CEO at Metalysis (pictured, far right), said: "Metalysis is proud to mark our commitment to the region by joining the Northern Powerhouse Partners Programme.

"During our time with MP Richard Harrington and his colleagues, we have enjoyed discussing Company ambitions for our technology as part of the national agenda set forth in the Industrial Strategy.

"We look forward to working with the Northern Powerhouse, its networks and BEIS to strengthen international interest and investment in the overwhelming potential of the Northern economy."

Jake Berry, Northern Powerhouse Minister, added: "Supporting research and innovation is at the heart of our modern Industrial Strategy so I’m pleased to welcome Metalysis as our latest Northern Powerhouse partner.

"As an ambitious Yorkshire-based company with a commitment to boosting skills, technological development and growing production, they share our vision for a strong Northern Powerhouse economy."

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MP Richard Harrington visited Metalysis at its Materials Discovery Centre on the AMP to discuss the recent developments and hear about its ambitions for future expansion.

Work is already underway on "Generation 5" - manufacturing options for thousands of tonnes per annum of these high value metal alloy powders. It is designed to retrofit into an existing industrial site.

Richard Harrington, Business and Industry Minister (pictured, second right), said: "From a Cambridge University breakthrough to a growing commercial operation that is supporting production on an international scale, Metalysis is a prime example of the strength and economic potential of the north.

"Through our modern Industrial Strategy, we are harnessing our research, innovation and manufacturing strengths to help even more businesses realise their economic potential and apply them on an industrial scale – solidifying our position as a world-leader in advanced manufacturing."

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News: From Australia to Rotherham, Metalysis produces high value alloy

Rotherham-based Metalysis has produced a high value aluminium-scandium alloy as part of a pioneering R&D programme. It is expected to now be created on an industrial scale to support a drive for lighter materials in the automotive and aerospace industries.

The Manvers company holds the worldwide exploitation rights to a process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits.

Backed by investors, experts at the multimillion pound Materials Discovery Centre on the Advanced Manufacturing Park (AMP) in Rotherham, are carrying out bespoke, commercial R&D projects to produce exotic metal powders for high performance alloys in the aerospace and automotive industries.

Progress on the aluminium-scandium ("AlSc") alloy programme shows that the Metalysis' process could address challenges that have historically restricted the industrial use of scandium despite its excellent properties.

Scandium is a relatively scarce, high-value mineral used to produce aluminium alloys. Scandium-reinforced alloys are suitable for the manufacture of weldable aluminium products such as car chassis, car panels and aircraft fuselages and other light transport applications.

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Metal exploration business, Australian Mines Ltd, has provided a high purity scandium oxide from its Sconi site in North East Australia and Metalysis has now qualified it as a feedstock for next-generation scandium alloy.

The findings are set to benefit Metalysis' Materials Manufacturing Centre in Manvers, which houses its "Generation 4" industrial scale production facility.

Earlier this year the firm raised £12m ahead of the start of commercial production which began in September and means that it can now produce tens-to-hundreds of tonnes per annum of high value, niche and master alloys.

Ian Mellor, managing director of Metalysis' Materials Discovery Centre, said: "We are pleased by the rapid progress made during first phase R&D with Australian Mines. The provision of high quality scandium oxide from the Sconi project has enabled our teams to make a strong start and quickly complete proof-of-principle activities for the alloy feedstock addition using Metalysis' process.

"We look forward to reporting results to come as, together, we target the development of a high value AlSc alloy in sync with Australian Mines' production plans for Sconi, and Metalysis' production plans for Generation 4."

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Benjamin Bell, managing director at Australian Mines, added: "I am delighted that we have continued to make progress in our work with Metalysis and explore the potential to unlock additional economic value from scandium oxide to be produced at Sconi.

"By being involved in full end-to-end production this represents an appealing value proposition for our investors as opposed to the more typical mining and shipping ore approach. The fact that our scandium oxide product has been verified as meeting the specifications required to produce a master alloy puts us in an extremely strong position in our negotiations with potential scandium oxide off-take partners."

The technology presents opportunities to reduce all-in costs and environmental footprints compared to traditional, melting production routes. The Metalysis technology produces metal powder directly from oxide using electrolysis.

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News: Metalysis powers up industrial scale plant in Rotherham

Innovative firm, Metalysis is powering up a world-first commercial plant following millions of pounds of investment at its Materials Manufacturing Centre in Rotherham.

The Manvers company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. It is in the process of commercialising the technology to produce titanium, tantalum, and related high value alloys. These are used increasingly by major worldwide industries such as aerospace, marine, medical, chemical, automotive and electronics.

The finished facility at Manvers means that it can now produce tens-to-hundreds of tonnes per annum of high value, niche and master alloys.

Backed by investors and grants, the Cambridge University spin out secured £20m in 2016 and invested in a new Materials Discovery Centre on the Advanced Manufacturing Park (AMP), also in Rotherham. Earlier this year the firm raised a further £12m ahead of the start of commercial production in Rotherham.

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The so-called "Generation 4" technological expansion signifies Metalysis' transition into commercial production following more than a decade of phased technology development.

Being modular, production can be ramped up in phased expansions. The technology has also presented opportunities to reduce all-in costs and environmental footprints compared to traditional, melting production routes. The Metalysis technology produces metal powder directly from oxide using electrolysis.

The project has also created a UK source of supply. Metalysis has been working with partners in Canada and Australia to create a supply chain outside of China for rare-earth-element (REE) oxides and alloys.

Another major benefit of Metalysis' technology is its multi-metal capability, which enables the company to produce alloy "recipes" that comparable processing routes cannot. Where conventional technologies are unable to elegantly combine elements with melting and density differentials, this technology can because it is a solid-state process.

One recently announced R&D programme focuses on a high value aluminium-scandium alloy. Scandium is a relatively scarce, high-value mineral used to produce aluminium alloys. Scandium-reinforced alloys are suitable for the manufacture of weldable aluminium products such as car chassis, car panels and aircraft fuselages and other light transport applications.

Although there are primary production scenarios under development, it is largely mined as a by-product with little surety of supply. As an alloy addition, scandium can as much as triple manufacturing costs at current pricing.

The Gen4 project was mechanically completed on time in the fourth quarter of 2017. It has since undergone hot commissioning, trial runs, optimisation and handover to Operations.

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Dr. Dion Vaughan, chief executive officer at Metalysis, said: "In powering up and operating our industrial plant, Metalysis is poised to achieve its target to generate significant profits from our new South Yorkshire production facility.

"Ours is a true British success story with international implications. Metalysis has grown from the "lightbulb moment" at Cambridge University in the late-1990s, relocated to South Yorkshire to benefit from regional excellence in operational skillsets in the early-2000s, and now onwards towards a bright commercial future.

"We share this achievement with a number of partners, notably our plant-builder, K Home International, and our shareholders who have supported the journey."

Work is already underway on "Generation 5" - manufacturing options for thousands of tonnes per annum of these high value metal alloy powders. It is designed to retrofit into an existing industrial site.

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News: Australian Mines joins Metalysis R&D project

Metal exploration business, Australian Mines Ltd, has joined with Rotherham-based Metalysis and other partners on an R&D programme focused on a high value aluminium-scandium alloy.

The Manvers company holds the worldwide exploitation rights to a process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits.

Backed by investors, experts at the multimillion pound Materials Discovery Centre on the Advanced Manufacturing Park (AMP) in Rotherham, are carrying out bespoke, commercial R&D projects to produce exotic metal powders for high performance alloys in the aerospace and automotive industries.

The aluminium-scandium ("AlSc") alloy programme has affirmed the view that Metalysis' process could address challenges that have historically restricted the industrial use of scandium despite its excellent properties.

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Scandium is a relatively scarce, high-value mineral used to produce aluminium alloys. Scandium-reinforced alloys are suitable for the manufacture of weldable aluminium products such as car chassis, car panels and aircraft fuselages and other light transport applications.

Although there are primary production scenarios under development, it is largely mined as a by-product with little surety of supply. As an alloy addition, scandium can as much as triple manufacturing costs at current pricing.

Cost and supply constraints are two challenges Metalysis has focused on - its electrochemical technology is capable of producing a wide range of metals and alloys at a lower cost and environmental footprint than traditional melting processes.

Metalysis has already demonstrated an ability to produce an AlSc master alloy containing 15 times the amount of scandium compared to conventional industry processes.

Now Australian Mines is utilising its demonstration plant in Perth to deliver the high-purity scandium oxide to Metalysis, under this R&D partnership. The company is focused on production and supply of battery and technology metals.

An update to the Austrailian stock exchange said: "The ability for Australian Mines to produce a scandium-rich master alloy via Metalysis' solidstate process that contains up to 30% scandium metal (compared to the industry's current 2% scandium metal), could result in up to a 93% reduction in the amount of scandium master alloy required to produce the final aluminium – scandium metal requested by end-users.

"This could equate to a significant reduction in the cost of producing the final aluminium – scandium metal to a level that the contract price offered by Australian Mines for these lightweight aluminium products are materially lower than most other specialty metals currently available on the market."

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Metalysis said that the R&D programme is also destined to benefit the company's Materials Manufacturing Centre in Manvers, which houses its "Generation 4" industrial scale production facility.

Being modular, Gen4 builds on Generations 1-3 of Metalysis' technology and is capable of producing hundreds of tonnes of speciality powder alloys. A high value AlSc alloy continues to prove compelling as a potential launch product when Gen4 commercial production commences later in 2018.

£12m in funding was secured earlier this year and work is already underway on "Generation 5" - manufacturing options for thousands of tonnes per annum of these high value metal alloy powders. It is designed to retrofit into an existing industrial site.

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News: Metalysis and the Ministry of Defence

Metalysis, the Rotherham-based innovator, is playing a key role in helping Britain's Armed Forces to save time and money in their use of titanium in important defence applications.

The Manvers company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. It is in the process of commercialising the technology to produce titanium, tantalum, and related high value alloys. These are used increasingly by major worldwide industries such as aerospace, marine, medical, chemical, automotive and electronics.

Backed by investors and grants the Cambridge University spin out has secured over £30m of investment and opened a Materials Discovery Centre in a 22,000 sq ft unit on the Advanced Manufacturing Park (AMP), also in Rotherham. It is also scaling up production of titanium at its Farfield Park premises.

The MoD's Defence Science and Technology Laboratory (Dstl) in Porton Down has revolutionised the production of titanium by reducing the 40 stage process down to just two steps and potentially halving the cost. It is based on the FASTForge project being carried out at the University of Sheffield which relies on Metalysis technology.

The current $10 billion titanium market size is constrained by the cost of the metal and is poised to expand rapidly if the cost can be lowered. Titanium is as strong as steel and half the weight - but around ten times the cost.

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The Metalysis technology, which produces metal powder directly from oxide using electrolysis, has the potential to significantly increase production volumes. The process uses less energy and also means that innovative alloys can be tailored to have the desired properties for specific applications.

Defence Secretary Gavin Williamson said: "Our Armed Forces use titanium in everything from cutting-edge nuclear submarines and fighter jets through to life-changing replacement limbs - but production time and costs mean we haven't always used it. This ground-breaking method is not only faster and cheaper but could see a huge expansion of titanium parts and equipment throughout the military. It is a clear example of how our world-class scientists are working behind the scenes to help our Armed Forces as well as bringing prosperity and security to Britain."

Titanium's high strength, light weight and corrosion resistance sees it widely used in defence, in military aircraft and submarines, but its high production costs make it difficult to justify in all but essential areas.

Dstl has invested almost £30,000 in the new research project at the University of Sheffield, which led to the development of the new ground-breaking manufacturing process.

Dr Nick Weston, research associate at the University of Sheffield, said: "FAST-forge is a disruptive technology that enables near net shape components to be produced from powder or particulate in two simple processing steps. Such components have mechanical properties equivalent to forged product. For titanium alloys, FAST-forge will provide a step change in the cost of components, allowing use in automotive applications in automotive applications such as powertrain and suspension systems."

Funded by Innovate UK, the university is working with Metalysis, the Dstl, the Advanced Forming Research Centre (AFRC) and Safran Landing Systems.

In the laboratory, Field Assisted Sintering Technology (FAST) or Spark Plasma Sintering (SPS) exploits the Metalysis process and has been used to produce a shaped preform billet that is finished to near net shape using a one-step forging operation.

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News: Metalysis bags £12m for expansion

Innovative firm, Metalysis has raised £12m ahead of the start of commercial production in Rotherham.

The Manvers company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. It is in the process of commercialising the technology to produce titanium, tantalum, and related high value alloys. These are used increasingly by major worldwide industries such as aerospace, marine, medical, chemical, automotive and electronics.

Backed by investors and grants, the Cambridge University spin out confirmed some £10m of investment in its Rotherham facilities last year when it opened its Materials Discovery Centre on the Advanced Manufacturing Park (AMP).

The firm announced that the latest proceeds will fund state-of-the-art post-processing facilities, feedstock and provide working capital to support the rollout of its "Generation 4" technological expansion, taking production capability to new levels.

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Gen4 is an industrial scale production facility housed within Metalysis' Materials Manufacturing Centre at Manvers. Being modular, Gen4 builds on Generations 1-3 of Metalysis' solid-state, electrochemical technology. It is capable of producing hundreds of tonnes of high value, speciality powder alloys used in additive manufacturing, aerospace, automotive and other high value applications.

Work is already underway on "Generation 5" - manufacturing options for thousands of tonnes per annum of these high value metal alloy powders. It is designed to retrofit into an existing industrial site.

Fundraising participants comprised existing shareholders Woodford Investment Management, Draper Esprit PLC, ETF Partners and Interogo Treasury. Newcomers, Hercules Capital, Inc. of California, is also investing in Metalysis having pledged more than $7 billion to high-growth, innovative venture capital-backed companies in life sciences, sustainable and renewable technology industries since its inception.

Dion Vaughan, CEO of Metalysis, said: "Naturally, we are pleased that Metalysis has attracted financial backing from both new and existing sophisticated institutional investors.

"The expansion project carried out during the past year, combined with these proceeds, will support our multi-metal production and commercial rollout.

"Metalysis is a high growth UK technology business with advanced materials breakthroughs and solid-state production of great value to its customers, shareholders, partners, and employees."

Following last year's expansion, job numbers at the firm have grown to over 100.

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News: Canadian government R&D contract for Metalysis

Innovative Rotherham firm, Metalysis, has landed another overseas Research & Development contract regarding the creation of alloys from rare earth elements.

The Manvers company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. It is in the process of commercialising the technology to produce titanium, tantalum, and related high value alloys. These are used increasingly by major worldwide industries such as aerospace, marine, medical, chemical, automotive and electronics.

Backed by investors and grants, Metalysis, a Cambridge University spin out, secured £20m of investment and opened a Materials Discovery Centre in a 22,000 sq ft unit on the Advanced Manufacturing Park (AMP), also in Rotherham. It is also scaling up production of titanium at its Farfield Park premises.

Natural Resources Canada (NRCan), has now announced a new contract for work on the production of rare-earth-element (REE) oxides and alloys. And experts from Metalysis will be involved.

NRCan is the Canadian government department that oversees the responsible development and use of Canada's natural resources and the competitiveness of Canada's natural-resources products.

During the research project, REE solutions will be prepared at the facilities of Ontario-based Process Research Ortech Inc., followed by the precipitation and calcination of REEs from these solutions to produce high-purity REE oxides. Innovation Metals Corp. (IMC) will then work with Metalysis to study the co-reduction of the REE oxides with other metals to produce REE alloys.

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Last year Metalysis formed with Mkango Resources Ltd, a Canadian listed mineral exploration and development company, to work on rare earth permanent magnets that are at risk of shortage. It is also working with Kazakhstan to develop high value metals and alloys for additive manufacturing.

Dr Gareth Hatch, president of Innovation Metals Corp, said: "The cost-effective production of REE metals and alloys from separated REE oxides is an essential component of developing an independent REE supply chain outside of China.

"This project is a natural progression of our previously successful work on the production of separated REE oxides via IMC's RapidSX process. We look forward to working with Metalysis to demonstrate an effective, integrated path for REE alloy production."

REEs exhibit a range of special properties. Their use in components manufactured from a wide range of REE alloys and compounds are essential to the performance of numerous engineered systems for the green-energy, electronics, defense, aerospace and other sectors.

Dr Ian Mellor, managing director of Metalysis' Materials Discovery Centre, said: "We are pleased to partner with IMC and NRCan and eagerly anticipate the results of combining our know-how during this project.

"Metalysis' process can produce a wide range of advanced alloys and REEs are an area of substantial research interest, which we look forward to exploring together."

Canada is investing in R&D as it has significant critical metal reserves and an opportunity to supply some of the global demand.

Honourable Jim Carr, Canada's Minister of Natural Resources, said: "This research supports the Government of Canada's commitment to a low-carbon future. Environmentally friendly and energy-efficient technologies will drive Canada's sustainable growth in the mining sector for generations to come."

The research project is expected to be completed in the Spring of 2018.

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News: Metalysis rare earth project gets financial backing

Noble Group, a $46 billion turnover company that manages a portfolio of global supply chains across a range of industrial and energy products, is taking a serious interest in a research project being undertaken by innovative Rotherham firm, Metalysis.

The Manvers company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. It is in the process of commercialising the technology to produce titanium, tantalum, and related high value alloys. These are used increasingly by major worldwide industries such as aerospace, marine, medical, chemical, automotive and electronics.

Metalysis recently started a second phase of research into 3D printed permanent magnets which could help solve a potential crisis in the electric vehicle industry.

Earlier this year a partnership was formed with Mkango Resources Ltd, a Canadian listed mineral exploration and development company, to work on rare earth permanent magnets that are at risk of shortage.

The first phase saw the production of a neodymium-iron-boron ("NdFeB") alloy powder achieved using Metalysis' solid-state technology which uses electrochemical reduction to transform metal oxides, such as ores, directly into metal powders in a single step.

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Mkango has now announced that an agreement has been signed that will see Talaxis fund the development of its Songwe Hill Rare Earths Project in Malawi and the commercialisation of new magnet technologies.

Talaxis is a wholly owned subsidiary of Noble Group Limited and was created to develop the cobalt, lithium and rare earth business.

Talaxis has agreed to fully fund a bankable feasibility study for Mkango's Malawi project in return for a 49% interest in the project. Talaxis will invest £12m and has the option to acquire a further 26% interest.

Mkango also revealed that it is considering establishing a new venture focused on neodymium alloy powders, magnet and other technologies, including its collaboration with Metalysis. Talaxis is investing £2m for a 49% interest in the new venture.

William Dawes, chief executive officer of Mkango, said: "This transaction is transformational for Mkango and for Malawi, and is a further endorsement of the company's strategy and potential. This Agreement significantly strengthens our balance sheet whilst ensuring that the company is fully funded to progress Songwe and our collaboration with Metalysis.

"It also comes at a pivotal time in the rare earth market with a very strong demand outlook for rare earths such as neodymium and praseodymium used in permanent magnets for electric vehicles, wind turbines and other clean technology applications.

"We are very excited to be working with Talaxis, and moving forward with the bankable feasibility study for Songwe and Phase II of the research and development programme with Metalysis."

Mkango said that the proceeds will be used to fund the Phase II R&D programme with Metalysis. One opportunity identified in the programme includes evaluating the UK as a future host country for a manufacturing plant to exploit a commercialised technology.

Backed by investors and grants, Metalysis, a Cambridge University spin out, secured £20m of investment last year and recently opened a Materials Discovery Centre in a 22,000 sq ft unit on the Advanced Manufacturing Park (AMP) in Rotherham. It is also scaling up production of titanium at its Farfield Park premises.

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News: Metalysis and manufacturing on the Moon

Innovative technology pioneered in Rotherham by Metalysis has been recognised by the European Space Agency (ESA) for the important role it could play in colonising the Moon.

The Manvers company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. It is in the process of commercialising the technology to produce titanium, tantalum, and related high value alloys. These are used increasingly by major worldwide industries such as aerospace, marine, medical, chemical, automotive and electronics.

The agency, which brings together the resources of 22 member states, recently launched a challenge focusing on in-situ resource utilisation (ISRU) which concerns the exploitation of the lunar or asteroid resources enabling the in-situ supply of materials needed for building habitats and potentially empowering human beings to perform activities in space.

Metalysis is involved in a research and development (R&D) project as scientists have found a number of "raw materials" on the Moon which have the potential to be mined and converted into usable materials using the firm's electrochemical process. Lunar ilmenite could be transformed into titanium-iron alloys, lunar anorthite could be reduced to aluminium-silicon alloys, and lunar olivine could be transformed into magnesium-silicon alloys.

The powder alloys, created at much less the cost of current processes, are perfect for 3D printing, opening up the possibility of manufacturing building blocks and moving parts for machines, in-situ, on the Moon, out of moon rocks.

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Backed by investors and grants, the Cambridge University spin out secured £20m of investment last year and has opened a new Materials Discovery Centre on the Advanced Manufacturing Park (AMP) in Rotherham where it carries out bespoke, commercial R&D projects to produce exotic metal powders for high performance alloys in the aerospace and automotive industries.

In Manvers the company is completing its "Generation 4" technological expansion, taking production capability to new levels. Following next year is "Generation 5" - manufacturing options for thousands of tonnes per annum of high value metal alloy powders.

At a public ceremony at the end of the recent Global Space Economic Workshop in Paris, Eric Morel de Westgaver, Director for Industry, Procurement and Legal Affairs, at the ESA presented Dr. Dion Vaughan with a certificate naming Metalysis as first ESA "Grand Challenger."

Dr. Dion Vaughan, CEO of Metalysis, said: "An R&D project which contemplates taking our technology and applying it to 3D printing systems in terraforming environments is an ambitious undertaking, enabled by our next phase of scale-up in the UK.

"ESA's focus on developing transferable technologies, with industries offering economic benefits on earth and in space, is an excellent fit for Metalysis as we progress to our Generation 5 project which will showcase multiple modular electrochemical units, adjustable within a Factory of the Future manufacturing scenario."

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News: Metalysis make progress in magnet metal research

Innovative Rotherham firm, Metalysis, has started a second phase of research into 3D printed permanent magnets which could help solve a potential crisis in the electric vehicle industry.

The Manvers company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. It is in the process of commercialising the technology to produce titanium, tantalum, and related high value alloys. These are used increasingly by major worldwide industries such as aerospace, marine, medical, chemical, automotive and electronics.

Backed by investors and grants, the Cambridge University spin out secured £20m of investment last year and recently opened a Materials Discovery Centre in a 22,000 sq ft unit on the Advanced Manufacturing Park (AMP) in Rotherham. It is also scaling up production of titanium at its Farfield Park premises.

Earlier this year Metalysis formed a partnership with Mkango Resources Ltd, a Canadian listed mineral exploration and development company, to work on rare earth permanent magnets that are a critical component of many electric vehicles, as well as other consumer and green technologies, and are at risk of shortage.

Mkango has now secured a further £500,000 to support the commencement of a Phase II R&D programme with Metalysis.

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The project is focused on mining rare earth elements (REE) and associated minerals in the Republic of Malawi, and the parties envisaged a comprehensive research and development programme, culminating in the joint pursuit of commercial opportunities. One such opportunity includes evaluating the UK as a future host country for a manufacturing plant to exploit a commercialised technology.

The first phase saw the production of a neodymium-iron-boron ("NdFeB") alloy powder achieved using Metalysis' solid-state technology which uses electrochemical reduction to transform metal oxides, such as ores, directly into metal powders in a single step.

NdFeB alloys are used to make permanent magnets and an exclusivity agreement has now been signed for advanced alloys using neodymium or praseodymium with other elements for magnet manufacturing.

Neodymium oxide prices have approximately doubled since the start of the year, and Mkango said that the supply - demand outlook for rare earths used in permanent magnets is very positive.

Dion Vaughan, chief executive of Metalysis, said: "We are very pleased to commence Phase II of our R&D programme with Mkango. Producing a neodymium-iron-boron alloy illustrates the wide range of advanced alloys Metalysis' process can produce. We look forward to collaborating with Mkango over the coming months on this exciting project."

Other R&D projects currently being undertaken by Metalysis include one focused on a high value aluminium-scandium alloy that is being carried out with an international partner. It is also supporting the development of Kazakhstan's metal additive manufacturing industry with Metalysis technology used to develop metals and bespoke alloy powders suitable for additive manufacturing.

Metalysis is also part of the FASTforge project, alongside the Advanced Forming Research Centre (AFRC),the University of Sheffield and Safran Landing Systems.

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