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Titanium metal is sought after for its corrosion resistance and high strength-to-weight ratio. The element usually occurs in minerals such as rutile and ilmenite, which are mined for titanium dioxide production. The metal is conventionally extracted in a non-powder form from the minerals using the expensive Kroll process. Annual volumes of titanium market are estimated at ca. 143,000 tonnes with a market size worth c. USD 5 billion (source Titanium Metal Annual Review 2014).  However, many potential users have avoided titanium due to high price and limited availability. Powder prices for additive manufacturing range from USD 200 – 1,000+/kg.  By cutting the number of production steps the Metalysis process is capable of substantially reducing the cost of manufacturing high-purity Ti powder. The market impact of commercialising the Metalysis process could be significant if a low category titanium metal with the clarity to compete with other performance alloys ($4.4Bn) (source Roskill Minor Metals Conference 2013) and stainless steel ($110bn) source Roskill Minor Metals Conference 2013).

Industrial grade

  • Used in the petrochemical, desalination and medical industries
  • Corrosion resistant with a high strength to weight ratio
  • Bio-compatible and used as a alloyed structural product
  • Current market size is constrained by the cost of the metal.

Rutile grade

  • Metalysis had developed a unique powder product derived directly from ore feedstock
  • Ti powder may be used for automotive and industrial applications, displacing certain stainless steels and nickel-based alloys.




There are several commercial advantages offered by producing metal powder directly from the Metalysis process, including the ability to tailor the powder size, purity, morphology and the alloying elements. Metalysis have demonstrated production of titanium powders of various sizes down to below 100 μm. The flexibility of product form allows Metalysis to target a range of advanced powder metallurgy manufacturing methods that reduce material wastage.

Metalysis is currently working with commercial partners to test the suitability of powders for a range of applications from high end additive manufacturing through to use as a dopant in steelmaking. 

Titanium Alloys

Metalysis’ process is unique because it can produce alloys in the solid state that would be highly complex and expensive to manufacture by conventional melting techniques. This provides two significant opportunities for Metalysis. Firstly, the process can produce master alloys or pre-alloyed feed for conventional ingot producers. Secondly, it allows for the development of novel alloys with improved performance that will expand the current market for titanium products. Metalysis has provided samples of pre-alloyed products to commercial partners and is continuing product development.

For more information about our titanium products, please contact Dr Kartik Rao, via email (kartik.rao@metalysis.com)