Aluminum–scandium powder for 3D printing: Metalysis expands Western supply chains

The British materials manufacturer Metalysis is expanding its portfolio of metal powders to include high-purity aluminum–scandium alloy powder, which is particularly relevant for additive manufacturing, semiconductor technology, and aerospace applications. The move is driven by the growing demand for critical materials from non-Chinese supply chains, which is gaining further importance due to current export restrictions on rare earth elements.

Metalysis produces the aluminum–scandium alloy with a scandium content of 36 percent by weight in a fully homogenized form. The oxygen content is around 500 ppm, and the carbon content is approximately 50 ppm. These low levels of impurities are crucial for further processing into sputtering targets and for use as a feedstock in metal 3D printing, for example in powder-based processes such as laser powder bed fusion or binder jetting. The powder is available both in loose form and in consolidated form.

Technically, production is not based on conventional melting processes but on the company’s proprietary FFC Cambridge process. In this process, aluminum and scandium oxides are electrochemically reduced in a molten calcium chloride electrolyte at temperatures between 650 and 950 degrees Celsius. According to the company, this solid-state process enables uniform alloy formation with lower energy consumption and avoids the inhomogeneities that can otherwise occur in highly alloyed aluminum materials.

“Scandium alloys are increasingly replacing titanium and legacy aluminium alloy components in DoD systems due to their superior lightweight, high-strength characteristics”, Dr. Vic Ramdass, Acting Assistant Secretary of Defense for Industrial Base Policy, August 5th 2025.

For 3D printing, aluminum–scandium alloys are of particular interest due to their combination of low density, high strength, and good weldability. By selectively diluting the master alloy with aluminum, different scandium contents can be set, allowing adaptation to various mechanical requirements. Applications range from lightweight structural components to functional parts with increased fatigue resistance.

Nitesh Shah, CEO: “Metalysis has a clear strategy focused on premium critical materials. Our aluminium scandium alloy is fully homogenised and extremely low in impurities, making it ideal for high-performance applications in semiconductor manufacturing, whilst defence and aerospace manufacturers are exploring applications of lower scandium loadings. The recent REE export controls from China have accelerated urgent adoption of our aluminium scandium alloys, and we are now scaling production to meet this demand, moving from our Gen 2 units today to tonne-scale output from Gen 3 in the coming months.”

Metalysis currently operates several production facilities of different generations in southern England. While the current systems meet demand on the kilogram scale, larger facilities are expected to enable production on the ton scale in the coming years.