UK-based Metalysis has been selected by British rocket and space company Skyrora to develop and supply a novel advanced refractory alloy powder, Tanbium, for use in rocket engine components - specifically nozzle and combustion chambers - in a European Space Agency (ESA)–funded programme.
The partnership forms part of Skyrora’s award from ESA’s General Support Technology Programme (GSTP). Phase one will run for nine months and focus on de-risking the material production and testing its application via Additive Manufacturing (AM). The developed Refractory Complex Concentrated Alloy (RCCA), Tanbium, will be manufactured by Metalysis and demonstrated in rocket engine components using Skyrora’s in-house additive manufacturing system, Skyprint 2. This programme stage will raise the technology readiness level (TRL), with subsequent phases targeting TRL 6 for full-scale prototype testing in relevant environments. The other project partner is Thermo-Calc Solutions AB, who has designed and developed Tanbium using Integrated Computational Materials Engineering (ICME). Thermo-Calc Solutions will optimize Tanbium’s composition to Skyrora’s performance requirements in the project.
Upper rocket stage and satellite thruster components are typically made from Niobium Hafnium C103 or Inconel 718, but these materials have limitations in burn time, oxidation resistance, reusability, and weight. Thermo-Calc Solutions AB has computationally designed Tanbium, a tantalum and niobium-based alloy, to deliver higher-temperature strength, improved ductility, enhanced oxidation resistance, and better laser processability than incumbent alloys, with predictions that it can extend component lifetime and burn time, while reducing weight with no effect upon performance. European space component production forecasts indicate demand for around 20,000 kg of alloy powder over the next five years for space launch and satellites, based on C103 usage.
Skyrora chose Metalysis due to its world-leading expertise in demonstrating niche alloy and novel high-entropy alloy (HEA) powders, and its proven ability to deliver custom refractory alloys with precise physical and chemical characteristics. Metalysis’ patented FFC Cambridge electrolysis process enables the production of bespoke materials in the solid state, overcoming the alloying limitations found in traditional melting. This capability allows metals with very different chemical and physical properties to be combined, creating advanced alloys such as Metalysis’ unique HEA offering: lightweight refractory HEAs - at commercial scale - a breakthrough in materials science not seen since the Bronze Age. Furthermore, since the natural form of the alloy is a powder, it is suited to downstream consolidation techniques, such as Additive Manufacturing.
As a UK midstream metal and alloy producer, Metalysis operates from both its Discovery Centre at the Advanced Manufacturing Park, and its Manufacturing Centre in the Dearne Valley, both located in South Yorkshire. Its process outputs range from R&D grammes to tens of tonnes of industrial production. Metalysis employs nearly 50 people across scientists, trained operators and engineers.
Nitesh Shah, CEO Metalysis: “Metalysis is very excited to be participating in this ESA funded project – utilising our alloy and high entropy alloy experience to produce the new alloy Tanbium, which is predicted to significantly enhance space component lifetimes. Skyrora came to us as the advanced materials partner because only our solid-state process can produce such a vast range of novel alloys. We look forward to successfully completing stage 1 of this project and moving to stages 2 and 3, and so making a real impact within the space propulsion market”.
Derek Harris, Director of Business Development and Communications, Skyrora: “This project reinforces Skyrora’s commitment to sovereign launch capability and materials innovation. The UK and Europe are currently heavily dependent on the US for C103 alloy, which is used across aerospace propulsion. Tanbium will enable full domestic sourcing with the powder produced by Metalysis, and components printed and tested by Skyrora, which will be simulated by Thermo-Calc to optimise material behaviour before physical testing. As a European launch vehicle manufacturer, not only will Tanbium align with our long-term vision for sustainable, high-performance space hardware, but it will also contribute to the ESA’s Net Zero Space ambitions.”
Dr. Ida Berglund, Managing Director of Thermo-Calc Solutions: “Scaling up refractory alloy powder production requires precision and quality. This project, and Metalysis experience and expertise in producing high quality refractory powders, help us bring Tanbium to the space propulsion market faster.”
Simon Hyde – European Space Agency (ESA) Technical Officer: “Ultra-High Temperature capable materials for rocket motor applications are a key item in the ESA work plans. This project addresses the challenge in an outstanding way: It combines bespoke alloy design with a unique production approach. These technologies are perfectly wedded to laser powder bed fusion, additive manufacturing. Using this, Tanbium alloy, the consortium are addressing a critical challenge for ultra-high temperature applications in Europe. They are opening a potentially rich seam for space applications and providing Europe with a resilient supply chain.”
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Notes to editors
About Metalysis
Metalysis is a global leader in producing metal powders, alloy powders and high entropy powders for use in space, advanced electronics including semiconductors and capacitors, defence, hypersonics, engineering and construction, aerospace, clean energy, electric vehicles, AI, 5G and the IoTs. Deploying our patented FFC solid-state electrolysis process we can reduce metal oxides from 49 elements of the periodic table creating valuable metal, metal alloy and high entropy alloy powders.
Since 2019, Metalysis has emerged as the global leader in space exploration, having partnered with the European Space Agency and the UK’s space agency to extract oxygen from lunar regolith. Metalysis was approached because its electrolysis process liberates oxygen from metal oxides - employing an oxygen-evolving anode versus the conventional carbon, means that oxygen is the released gas – which can be captured, and when utilised in-situ on the lunar surface, can provide oxygen for propulsion and life support. Metalysis is the selected technology chosen by the European Space Agency (ESA) upon which all ESA oxygen extraction projects are being developed. Metalysis is also in conversations with commercial partners to accelerate the deployment of a larger scale unit – a Gen 2 and above - on the lunar surface.
Metalysis is a key-midstream asset for the UK and Her allies – providing domestic oxide reduction capabilities within the UK meaning critical materials and rare earth elements are not exposed to supply chain risks.
For more information
About Skyrora
Headquartered in Scotland with facilities located across Europe, Skyrora designs, manufactures, and deploys launch vehicles for small satellite manufacturers looking to access space. Skyrora’s strategy is to take an incremental ‘step-by-step’ approach to allow for critical testing and de-risking, utilising proven technology in combination with advanced additive manufacturing methods. In August 2025, Skyrora received its launch licence to commence a commercial orbital launch programme. Learn more at www.skyrora.com or follow us on Facebook, Instagram, LinkedIn, Twitter, or YouTube.
About Thermo-Calc Solutions
The company is a highly skilled team of scientists and engineers that applies cutting-edge computational modelling and simulation tools to solve industrial challenges by bringing innovative materials solutions from idea to market.
As the engineering services division of Thermo-Calc Software, the company leverages Thermo-Calc’s powerful suite of products to provide materials design, process simulation, and alloy optimization services, enabling clients to accelerate product development, reduce costs, and meet performance and sustainability targets.
With a global network, the company is in a unique position to bring the highest quality solutions to materials- and process-related issues, enabling innovators in industry to focus on their core business.