Metalysis expands production: New spheronization technology for high-performance powders

The British company Metalysis, which specializes in the production of metal and alloy powders using solid-state processes, has acquired a 40 kW Tekna spheronizer. This equipment enables the production of spherical powders for highly specialized markets with high added value and supports the development of new alloys on a small scale. With this investment, Metalysis is driving the production of high temperature alloys such as Tantalum, High Entropy Alloys and Niobium alloys such as C103 and FS85.

Proprietary FFC Cambridge electrolysis technology is at the heart of Metalysis’ metal production. In contrast to conventional smelting processes, this process reduces metal oxides in the solid state, which enables unique material properties. The non-spherical powders produced are suitable for applications in electronics, aerospace and energy technology. The new spheronizer extends these capabilities by optimizing powder properties such as flowability and packing density and reducing internal porosity.

A key advantage of the spheronizer is the production of spherical powder particles, which are essential for additive manufacturing processes such as 3D printing, metal injection moulding (MIM) or hot isostatic pressing (HIP). The technology also makes it possible to precisely tailor particle sizes to specific manufacturing methods, minimizing waste and energy consumption. Metalysis’ approach combines efficiency with sustainability, as in-house production reduces global supply chain risks and avoids transportation routes.

Nitesh Shah, CEO of Metalysis, remarked, “The acquisition of a 40 kW spheroidiser marks a major step forward in Metalysis’ capability to produce advanced powders in-house and serve our niche but high value markets – particularly in refractory alloys and lightweight refractory high entropy alloys. By controlling our spheroidisation processes, we’re not only reducing lead times and mitigating global supply chain risks, but also reinforcing our sustainable footprint. This is a pivotal moment for Metalysis as we strengthen our position in the critical materials supply chain – now able to provide spheroidised powders in-house.”