---
title: "Metalysis produces high-purity aluminum scandium alloy powder"
url: https://www.voxelmatters.com/metalysis-produces-high-purity-aluminum-scandium-alloy-powder/
date: 2025-12-17
modified: 2025-12-17
lang: en
author: "Edward Wakefield"
description: "Metalysis, a manufacturer of solid-state metal and alloy powders, is now producing high-purity aluminum scandium alloy (Al₃Sc) powder to meet rising demand from the semiconductor, aerospace, and defense sectors. The..."
categories:
  - "AM Powders"
  - "Materials"
  - "Metals"
  - "UK"
tags:
  - "insights"
image: https://www.voxelmatters.com/wp-content/uploads/2025/12/Metalysis_Al3Sc-1024x768-1-640x480.webp
word_count: 390
---

# Metalysis produces high-purity aluminum scandium alloy powder

[Metalysis, a manufacturer of solid-state metal and alloy powders](https://www.voxelmatters.directory/company/metalysis/), is now producing high-purity aluminum scandium alloy (Al₃Sc) powder to meet rising demand from the [semiconductor](https://www.voxelmatters.com/engineers-advance-semiconductor-manufacturing-with-3d-printing/), aerospace, and defense sectors. The development comes as Western manufacturers seek secure, non-Chinese sources of rare earth elements (REEs) and critical minerals. Based across two sites in South Yorkshire, UK, Metalysis is a strategically important midstream asset for the UK and its allies, aligning with the UK’s Critical Minerals Strategy: Vision 2035.

[Metalysis currently produces](https://www.voxelmatters.com/metalysis-increases-new-metal-alloy-powder-research-capabilities-by-33/) a high-scandium aluminium alloy containing 36 wt% / 25 at% scandium (64 wt% / 75 at% aluminium) in fully homogenised form. The material achieves oxygen levels of 500 ppm and carbon levels of 50 ppm, meeting the stringent purity requirements for semiconductor sputtering targets. It is supplied in powder form or as consolidated discs.

The 36 wt% alloy is used in sputtering targets for thin-film deposition of aluminium scandium nitride (AlScN). AlScN enables next-generation bulk acoustic wave (BAW) filters and resonators with enhanced piezoelectric performance, supporting advanced 5G and future networks, Wi-Fi expansion, AI applications, and the Internet of Things. Customers can dilute the alloy with aluminum to produce lower scandium loadings, enabling use as a master alloy for [aerospace and defense applications](https://www.voxelmatters.com/voxelmatters-aerospace-am-focus-2025-ebook/).

Unlike conventional melting routes, Metalysis uses its patented FFC Cambridge electrolysis process to co-reduce aluminium oxide and scandium oxide directly in molten calcium chloride at 650–950°C. This solid-state process consumes less energy, enables high scandium loadings, and delivers fully homogenised alloys with consistent performance.

Metalysis operates four Gen 2 units, each capable of producing up to 350 kg of Al₃Sc annually, addressing an estimated global market of 3–4 tonnes per year. Gen 3 units will enable tonne-scale output per unit, while Gen 4 units are designed for production at the tens-of-tonnes scale as demand grows.

"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," said Nitesh Shah, CEO of Metalysis. "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."