Metalysis acquires 40 kW spheroidizer from Tekna
The system is designed for the production of spherical powders for niche markets (like AM) and the discovery of new alloys at the development scale
Metalysis, a manufacturer of solid-state metal and alloy powders, has acquired a 40 kW spheroidizer from Tekna. This size of the spheroidizer is designed for the production of spherical powders for niche markets with high added value, and the discovery of new alloys at the development scale. This acquisition highlights Metalysis’ scaling-up production of its refractory alloys – which includes Tantalum and High Entropy Alloys – and plans to serve the high-temperature niobium market with materials such as Niobium C103 and FS85.
Using the patented FFC Cambridge electrolysis process, Metalysis reduces metal oxides in the solid state – a method that contrasts with traditional melting processes – and is able to deliver non-spherical powders exhibiting unique market-leading attributes required by its global customer base. The firm is focused on capacitor-grade tantalum, aluminum scandium alloys, and lightweight and refractory high entropy alloys. With these materials, Metalysis serves the capacitor, semiconductor, clean energy, aerospace, extreme environment, hypersonics, and space sectors.
The spheroidizer can meet the most demanding powder metallurgy applications, including additive manufacturing (AM), metal injection molding (MIM), spark plasma sintering (SPS), and hot isostatic pressing (HIP). It enhances Metalysis’ in-house capabilities – improving attributes such as powder flowability, reducing internal porosity, and delivering higher packing density.
Typically, the Metalysis FFC Cambridge process outputs powders with an angular shape – thus the spheroidizer is able to produce spherical particles for powder metallurgy applications.
A key feature of the Metalysis FFC Cambridge technology is the ability to tailor particle size for a given AM technique whilst generating minimal under or oversize particles. This characteristic is maintained post-spheroidization – resulting in negligible waste powder being created compared to conventional atomization processes, and consequently, energy is not consumed in the generation of scrap powder.
By bringing spheroidization in-house, Metalysis enhances its vertically integrated production model – reducing lead times, mitigating global supply chain risks, and significantly tightening its sustainable footprint. This move eliminates the need to transport materials around the world.
“The acquisition of a 40 kW spheroidizer 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 spheroidization 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 spheroidized powders in-house,” said Nitesh Shah, CEO of Metalysis.
