Metal Powder Technology Summer 2025 by Inovar Communications

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Metal powders, supply chain resilience and the sustainability revolution

When it comes to the growing emphasis on regional supply chain resilience, metal powder-based technologies are at the forefront of developments.

The lead article in this issue of Metal Powder Technology magazine reports on GKN Powder Metallurgy’s expansion into NdFeB magnet production – an area of increasing importance for the electric vehicle and wind power supply chains. Given that most magnets are currently produced in China, the company’s mission to establish regional magnet production in Europe and North America is an important strategic step.

Further, the company is also reducing or eliminating the use of heavy rare earth elements (HREEs) in its magnets, strengthening the supply chain and reducing exposure to material price volatility.

We also focus on the rise of lithium iron phosphate (LFP) batteries, which are set to become the dominant technology for EVs over the next decade, and highlight the significant opportunities that exist for iron powder producers.

Meanwhile, the HIP2025 conference in Aachen outlined the crucial role of Hot Isostatic Pressing (HIP) in the industrial supply chain, in particular its central role in building the next generation of nuclear power stations.

It seems that wherever we look, metal powder-enabled solutions are never far away.

Nick Williams Managing Director Metal Powder Technology

Cover image

The wire cutting of NdFeB magnets in Radevormwald (Courtesy GKN Powder Metallurgy)

METAL POWDER

55 GKN Powder Metallurgy targets sustainable and resilient regional NdFeB magnet production

As the shift to vehicles with electrified powertrains gathers pace, the need for sustainable, locally produced highperformance magnets has become critical. GKN Powder Metallurgy is rising to this challenge by establishing NdFeB magnet production in Europe and North America, with a focus on reducing or eliminating the use of heavy rare earth elements (HREEs) such as terbium and dysprosium.

In this article, Gordon Hutchinson, Vice President Magnets, outlines the company’s progress, technology strategy, and vision for a resilient magnet supply chain. >>>

65 The chemistry of LiFe: The rise of LFP batteries and what it means for the iron powder industry

For those less familiar with the chemistry, Robert Mitchell, Principal Scientist in Energy Materials at CPI, offers a comprehensive overview of LFP’s structure, performance, and evolving production methods, and explores why LFP batteries are poised to become a major consumer of iron powders. >>>

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77 Driving sustainable innovation: HIP 2025 explores the strategic potential of Hot Isostatic Pressing

As RWTH Aachen’s Yuanbin Deng, Felix Radtke, Ziping Sang, Jonas Koob, Frederik Tegeder, and Anke Kaletsch report, HIP 2025 highlighted the technology’s strategic value in enabling safe, reliable, and sustainable manufacturing for demanding applications. >>>

87 High-precision press solutions for permanent magnets in EVs and green energy generation

This article explores the role of pressing technologies in magnet manufacturing, with a focus on DORST Technologies’ solutions designed to ensure consistent quality, material efficiency, and process control in modern magnet production. >>>

95 Powder2Powder: A closedloop solution for high-value metal powder recycling

As sustainability becomes a strategic imperative in advanced manufacturing, the ability to recycle high-value metal powders is critical.

Amazemet’s Powder2Powder module enables closed-loop reuse of off-specification or waste powders through plasma melting and ultrasonic atomisation. This compact system restores key powder characteristics –including sphericity, particle size distribution, and chemical uniformity – making them suitable for AM processes.

Tomasz Choma explains how the technology enables manufacturers and researchers to reduce waste, lower costs, and enhance material efficiency.

103 Reducing defects and energy use in Hot Isostatic Pressing: A data-driven approach to degassing

This article introduces a datadriven solution: Gencoa Ltd’s Optix system, which uses remote plasma optical emission spectroscopy (RPOES) to enable real-time monitoring of gas species. By bringing precision and traceability to degassing, Optix helps manufacturers reduce defects, shorten cycles, and cut energy consumption.

To submit news for inclusion in Metal Powder Technology contact Paul Whittaker at paul@inovar-communications.com

YASA opens UK-based axial flux motor facility with capacity to produce 25,000 annually

YASA Ltd, a wholly-owned subsidiary of Mercedes-Benz Group AG, has opened a newly upgraded manufacturing facility in Yarnton, near its Oxford, UK, headquarters. Following a £12 million investment, the new factory will boost YASA’s axialflux electric motor manufacturing capacity to over 25,000 units per year. Reported to be the world’s most advanced axial-flux electric motor manufacturing facility, the Yarnton operation is also the UK’s first axial-flux electric motor super factory.

“With a multi-million-pound investment into our Yarnton facility, we have transformed our manufacturing capability and significantly accelerated our production capacity,” stated Tim Woolmer, YASA CTO and founder. “This latest initiative will enable us to apply our technology with even greater accuracy, pace and scale. Combined with YASA’s position as part of the Mercedes-Benz Group, the factory transformation consolidates YASA’s role as a global leader in developing high-performance, high-efficiency axial-flux e-motors.”

Developed for electric and hybrid vehicles, YASA’s axial flux motors deliver up to four times greater performance than other electric motors on the road today. The design contains stators made from soft magnetic composite (SMC) powders.

“As a company, we have come a long way since our humble origin as an Oxford University startup. However, we are still driven by the same passion, spirit and

determination to create the world’s most advanced electric mobility technology solutions,” continued Woolmer.

The new 5,600 m 2 facility incorporates cutting-edge manufacturing technologies designed specifically to meet YASA’s requirements. These include the addition of four new, uniquely constructed coil and bar manufacturing cells with state-ofthe-art CNC coil winding, assembly and impregnation processes. New laser stripping and brazing, increased rotor balancing accuracy, new high-capacity ovens, stator laser welding and complete stator quality control, cover dimensional, electrical and leak testing.

The facility brings all production processes under one roof, with significantly enhanced automation and highly efficient production lines. The company stated that these advances will enhance YASA’s capability to create complete motor

Users of YASA’s axial flux technology include both Ferrari and Lamborghini, as well as Mercedes Benz (Courtesy YASA Ltd)

sets while improving repeatability and reliability and introducing even greater flexibility levels by overcoming bottlenecks in the component supply chain.

YASA’s longstanding relationship with the Advanced Propulsion Centre UK (APC) is reported to have helped enable the original development of its Yarnton facility. While this latest expansion has been privately funded, YASA continues to work closely with the APC on future generations of axial flux technology.

www.yasa.com

YASA has invested £12 million to upgrade manufacturing at its facility in Yarnton, Oxford, UK (Courtesy YASA Ltd)

Gevorkyan reports strong start to 2025 with major defence and automotive contract wins

Gevorkyan a.s., headquartered in Vlkanová, Slovakia, has reported a successful start to 2025, with Q1 revenues of €20.88 million and statutory EBITDA of €8.35 million, resulting in an EBITDA margin of almost 40%. This represents an increase in revenues of 11.2% and an increase in EBITDA of 14.35% compared to the same period of the previous year. The company reported an operating EBIT of €4.21 million, an increase of 7.15% compared to the same period last year. The profit after tax (EAT) was reported at €2.98 million, representing a 26.32% increase compared to the same period last year.

“Our strong performance in an uncertain economic environment underlines our resilience and ability to use global uncertainties to our advantage,” stated Artur Gevorkyan, Chairman of the Board “We are optimistic about our plans and will combine organic growth with selective and value enhancing acquisitions.”

In the announcement, the company reported that it has won nine new long-term projects in the arms industry for the European and American markets. Following the success at a recent international trade fair, an agreement was signed to develop components for sporting arms in the USA.

offers

Tekna receives major orders for titanium MIM powder totalling CA$5.2 million

Tekna Holding ASA, Sherbrooke, Quebec, Canada, has announced it has received three orders, valued at a total of CA$5.2 million, for titanium powder used in Metal Injection Moulding. The orders are scheduled for delivery in 2025 and 2026.

“These sales have historically been strong contributors to our cash flow, and it is reassuring to now have multiple customers for this material,

signalling an increase in demand and potential for margin improvement,” said Luc Dionne, CEO of Tekna.

The three customers are reported to be Tier 1 component manufacturers based in Asia. They plan to use the titanium powder to mass-produce sub-components such as digital watch cases, hinges, and buttons.

Rémy Pontone, VP Sales and Marketing, added, “These orders are

At the same time, mass production of components for a $30 million project that the company won in a 2024 tender, has now started.

The first phase of a project for a European manufacturer of optoelectronic devices using night vision, thermal imaging, and laser technology has been successfully completed. In the next phases, development and mass production for new applications in armaments and aerospace will continue.

In the automotive segment, new projects for autonomous robotic taxis have been acquired in the US and Europe. Additionally, after several years of technical and commercial negotiations, the company won a project for the petrol station and oil industry in the USA.

The company reports that it has also received orders from Europeanbased customers, notably one to supply a European plant wholly owned by a renowned Asian brand. Following the rapid and successful completion of development based on specific customer requirements, series production is scheduled to ramp up soon.

As part of investments in new premises, automation and robotisation, Gevorkyan reported that a warehouse and production area were expanded by approximately 1,000 m². In Q1 2025, a project to robotise two calibration presses was also completed, helping further reduce operational costs.

www.gevorkyan.sk

for material consisting of smaller particles from our existing powder production, which is partly available in our inventory and partly from ongoing production. It plays a key role in our strategy to maximise sales from Tekna’s entire production yield. Through collaboration with our customers, we have successfully qualified this smaller cut size for MIM, improving resource efficiency, increasing sales yield, and significantly expanding our market share within the consumer electronics components industry.”

www.tekna.com

Gevorkyan

Powder Metallurgy, Metal Injection Moulding, Hot Isostatic Pressing and metal Additive Manufacturing services (Courtesy Gevorkyan)

Press Systems for Shaping Magnets & Magnetic Materials

Less Common Metals to establish €110M facility in France to support EU rare earth supply chains

Less Common Metals (LCM), headquartered in Ellesmere Port, UK, has announced plans to invest €110 million in developing a production facility in France for light and heavy rare earth metals and alloys. The company stated that Lacq is currently being considered as the location for the plant, with a final decision due shortly. The move is anticipated to create up to 140 highly skilled jobs

and support the development of a more robust, resilient rare earth supply chain.

LCM has more than thirty years of experience in the rare earth industry and holds a unique position as one of the few non-Chinese producers of rare earth metals and alloys. It plays a crucial role in the midstream of the rare earth supply chain, providing essential materials for permanent magnets

Sun Metalon receives further $9M funding to support its metal industry decarbonisation plans

Sun Metalon Inc, headquartered in Wood Dale, Illinois, USA, with operations in Japan, has announced it has received $9.1 million in investment following the successful closing of its second Series A funding round. This follows the first closing announced last year, bringing the total Series A funding capital to $39.8 million, including loan facilities. Investors in the round include Nippon Steel Corporation, the Japan Bank for International

Cooperation (JBIC), Airbus Ventures, and the Shimadzu Future Innovation Fund (managed by Global Brain Corporation).

This newly raised capital is expected to aid the company’s expansion in both US and Japan locations. This will support Sun Metalon in accelerating the decarbonisation of the metal industry and advancing industry recycling.

“Our patented heating technology tackles both environmental and economic challenges by drastically reducing CO 2 emissions and

used in various applications. The company is involved in a wide range of European and UK-funded projects that drive innovation in product and process development. These collaborative projects are said to position LCM at the forefront of emerging technologies and reinforce the company’s ongoing contribution to the European academic, research, and development landscape.

“Choosing France for this strategic expansion marks an important milestone in our mission to develop a robust and complementary rare earth supply chain for the Western World,” stated Grant Smith, chairman of Less Common Metals.

“With over three decades of experience in rare earth metals and alloys, LCM is committed to deepening our partnerships across Europe and reinforcing regional supply chain resilience. France’s strong support, robust industrial base, collaborative research environment, and strategic positioning within Europe align closely with our vision to invest in critical materials development and build alternative supply chains,” concluded Smith.

www.lesscommonmetals.com

enabling efficient metal recycling, while recovering valuable metal resources and reducing operational costs,” stated Kazuhiko Nishioka, CEO of Sun Metalon.

“We are deeply grateful to everyone who believed in Sun Metalon’s vision and supported us in this funding round. This investment enables us to continue evolving our technology and delivering impactful solutions to a broader audience. I am especially honoured to work alongside strategic partners such as Nippon Steel Corporation, from whom I have gained invaluable experience and support over the years, as we build the future together,” Nishioka concluded.

www.sunmetalon.com

Less Common Metals has announced plans to open a facility in France (Courtesy Less Common Metals)

Hiperbaric to install large-scale HIP system at Plus Metal for aerospace components in Taiwan

Hiperbaric, located in Burgos, Spain, has reported it will install Hot Isostatic Pressing (HIP) equipment at Plus Metal, a Taiwanese company focused on manufacturing components for the aerospace industry. The system, a Hiperbaric HIP 93, is one of the largest in Hiperbaric’s portfolio and is set for installation at Plus Metal’s headquarters.

Hot Isostatic Pressing technology is critical for sectors such as aerospace, enabling the

production of parts with superior mechanical properties, increased resistance to fatigue and thermal stress, and the structural reliability essential for extreme operating conditions. HIP technology allows for the manufacturing of complex geometries with fewer internal defects and improved surface finishes, benefitting both Powder Metallurgy and Additive Manufacturing produced parts.

Plus Metal is strategically investing in HIP technology to

Plus Metal’s new Hiperbaric 93 HIP will be used for processing high-valueadded components for the aerospace sector (Courtesy Hiperbaric)

David Goulbourne appointed President of Sandvik Powder Solutions Division

Sandvik AB, headquartered in Stockholm, Sweden, has announced the appointment of David Goulbourne as the new President of the Powder Solutions division, effective May 1, 2025. The Powder Solutions division belongs to business area Sandvik Manufacturing and Machining Solutions, part of the Sandvik Group. The division includes the Osprey line of products as well as the Wolfram and Buffalo Tungsten brands. Goulbourne

will also be the President of Wolfram Bergbau und Hütten AG.

Goulbourne brings nearly twenty-five years of experience in the manufacturing industry and an entrepreneurial mindset. Before taking this role, Goulbourne held the position as Vice President Business Unit Solid Round Tools at Sandvik Coromant.

“I am thrilled to join the Powder Solutions division and contribute to

bolster its capabilities in the manufacturing of high-value-added components for the aerospace sector. “HIP technology ensures our company a robust position within the global landscape of advanced material applications, further solidifying Taiwan’s crucial role in the international aerospace supply chain,” stated Lin Zanshengm, chairman of Plus Metal.

Andrés Hernando, CEO of Hiperbaric, emphasised Hiperbaric’s 25 years of innovation and expertise in high-pressure technology, including water-based high-pressure equipment up to 6,000 bar (87,000 psi).

“This extensive experience has enabled Hiperbaric to develop modern HIP equipment with enhanced performance and reduced operational costs,” he added. Its coiled vessel technology not only offers advantages from a safety and reliability point of view, such as increased service life or the ‘leak before break’ design that avoids catastrophic failures but also provides advantages from a thermodynamic point of view. Being a coiled vessel, the cooling channels can be placed very close to the vessel wall and, therefore, very close to the hot zone, allowing the vessel to act as a heat exchanger, enabling fast cooling inside the equipment.

www.hiperbaric.com www.plus-tech.com.tw

strengthening and expanding our leadership in the powder manufacturing industry. My focus will be on ensuring that customer value remains our top priority, by continuously developing more sustainable processes and high-quality powder solutions,” said Goulbourne.

He will succeed Alex Nieuwpoort, who has decided to retire after twenty-eight years of dedicated service and significant contribution to Sandvik’s growth and business development. Nieuwpoort will remain with Sandvik until the end of June.

www.metalpowder.sandvik

Yuean New Materials reports 2024 revenue up 13.4% amid strong powder demand

Yuean New Materials, a leading supplier of MIM powders, feedstock, soft magnetic materials and carbonyl iron powders, based in China’s Jiangxi Province, has released its end-of-year results for 2024.

The company achieved revenue of 418 million yuan (approx $58 million), a year-on-year increase of 13.4%. Net profit for the year was 70.29 million yuan (approx $9.8 million), a year-on-year decrease of 12%, with net profit after deducting non-recurring items being 66.53 million yuan, a year-onyear decrease of 8.95%.

The company stated that the main reason for its revenue growth was the increased use of Metal Injection Moulding technology in

sectors such as consumer electronics and automobiles, replacing some traditional forging, casting, and similar processes to produce precision parts. This was said to have driven the company’s related powder product revenue growth and the increase in demand for downstream application products in electronic components.

Revenue from the company’s soft magnetic powder product line was 153 million yuan (approx $21.3 million), an increase of 19.1% year over year. Gross profit margin was 42%, a decrease of 5.4 percentage points year-over-year. The company said the main reason was that the fundraising and investment projects were converted into fixed assets, while production

capacity was still growing, and the operating costs, such as depreciation, increased.

The revenue of the carbonyl iron powder product line was 122 million yuan (approx $17 million), up 6.4% year-on-year, and the gross profit margin was 44.8%, down 4.9 percentage points year-on-year. The decline in gross profit margin was mainly due to the increase in raw material prices and production costs.

Regarding the total volume and development trend of the carbonyl iron powder industry, Yuean New Materials said in an interview with institutional investors in April this year that the global annual demand for carbonyl iron powder is about 30,000 tons, with a compound growth rate of about 20% in the past five years. If the price remains relatively stable, the annual increase in the existing market is expected to be about 10-15%.

www.yueanmetal.com

Forge Nano receives $40M to scale US battery and semiconductor production

Forge Nano, based in Denver, Colorado, USA, has announced the successful close of $40 million in new funding, bringing its total capital investment to over $140 million. Building on recent installations of a state-of-the-art battery manufacturing line and a cleanroom production facility for semiconductor ALD tool production at its headquarters, the company plans to use the latest $40 million investment for further domestic manufacturing and workforce expansion.

“RockCreek’s commitment to American manufacturing, energy security and global technology leadership makes them an ideal partner as we continue to scale,” said Paul Lichty, CEO of Forge Nano. “We look forward to expanding our domestic workforce as we scale our production capabilities and grow our customer base.”

The latest funding was co-led by RockCreek and Ascent Funds, with additional participation from Top Material, Orion Infrastructure Capital and Forge Nano’s existing

investors. In total, the company has seen investment from GM Ventures, Volkswagen, LG Technology Ventures, Hanwha, Mitsui Kinzoku, Sumitomo Corporation of Americas, Air Liquide, Catalus Capital and SBI Investment.

Forge Battery

The commercial lithium-iron production subsidiary of Forge Nano, Forge Battery designs and manufactures lithium-ion cells that incorporate critical minerals coated via Forge Nano’s Atomic Armor technology.

Manufactured using a predominantly US material supply chain, the company’s battery products are tailored in an effort to provide a secure supply chain and strong performance for defence, aerospace and specialty applications. In January 2025, Forge Battery received $100 million from the US Department of Energy (DoE) to expand cell manufacturing at the company’s North Carolina facility.

The TEPHRA

platform

Forge Nano’s TEPHRA platform, launched in mid-2024, is described

Nanoval and Ingpuls partner to advance nickel-titanium shape memory alloy powder production

After several years of collaboration, Nanoval, headquartered in Berlin, Germany and Ingpuls, located in Bochum, Germany, have entered into strategic cooperation to produce nickel-titanium (NiTi) shape memory alloys. The companies have decided to deepen their partnership to boost production capacities and reduce delivery times for customers.

“For years, we have been impressed by Ingpuls’s ability to produce rods of difficult alloys for us,” Christian Gerking, Managing Partner of Nanoval GmbH, stated.

“During recent mutual visits, we were also able to get to know the way of working, the career and the teams of both companies. In the exchange on site in Bochum, we were fascinated by the consistent and thorough approach of the Ingpuls team during the founding and development phase of the company, as well as the extraordinary dynamics of the company’s development in recent years, which can be traced back to an incredibly sustainable and farsighted commitment of the Ingpuls founders.”

by the company as ‘the world’s fastest single-wafer semiconductor atomic layer deposition coating tool with commercial throughput for 200 mm wafers.’ TEPHRA produces nano-coatings reportedly capable of producing chips with 40% faster processing speeds in an effort to address the industry’s growing demand for state-ofthe-art devices, sensors, and edge AI computing. The company’s ALD tools are engineered and built in the US.

“Forge Nano’s proprietary technology demonstrates that America continues to be the leader in innovation. Forge’s Atomic Armor significantly improves most battery chemistries with higher energy density, longer cycle life, faster charge speed, and lower risk of thermal runaway,” explained Mark Gordon, Managing Partner of Ascent Funds. “For semiconductors, Forge’s ALD removes a bottleneck to 3D chip stacking, allowing up to a 50% reduction in energy usage by chips. More efficient batteries are critical to national security. More efficient semiconductors will amplify the American lead in AI.” www.forgenano.com www.forgebattery.com

Dr Christian Grossman, member of the Ingpuls management board, added, “What is very exciting and strategically valuable is that demand from aerospace, medical technology, nuclear technology and research is very diversified. After the cooperation with Nanoval has grown over the years, we were able to define processes and production procedures in a strategic exchange, through which we are now able to significantly reduce delivery times,” Grossman continued. “This is very important for our customers, as it helps them to accelerate their development projects. Time to market is drastically shortened and everyone benefits.” www.ingpuls.de www.nanoval.de

Neo Performance Materials ships 18,000 magnet samples from new EU facility

Neo Performance Materials Inc, Toronto, Canada, has announced that its new permanent magnet facility in Estonia has shipped 18,000 sintered magnet samples, meeting specific magnetic properties, to a Tier 1 traction motor customer. The customer will assemble the magnet pieces into traction motors for performance testing. Production Part Approval Process (PPAP) products are scheduled for the first half of 2026, with mass production to start later that year.

“We are excited to announce this major milestone at our European magnet facility. Delivering the first product from a new facility is a momentous occasion,” stated Rahim Suleman, Neo CEO. “We take pride in our team’s dedication and hard work in winning the award, completing construction on time and on budget, and successfully transitioning the

facility into operational mode. This was a global effort for Neo, with our engineering and production teams in Estonia working hand-in-hand with our R&D and development teams in Singapore, Thailand and Europe. We also sincerely thank our customers for their unwavering support and partnership throughout this journey. Their collaboration has been instrumental in helping us achieve this milestone.”

With over thirty years of experience in rare earth magnetics, Neo has built a reliable global supply chain that supports its ability to serve the automotive sector. This industry expertise is expected to position Neo to successfully scale its new sintered magnet facility in Narva, Estonia, and support growing demand. The facility is strategically located near Neo’s rare earth separation facility in Sillamäe, Estonia,

IperionX secures $11M loan for titanium and Additive Manufacturing capabilities expansion

IperionX, based in Charlotte, North Carolina, USA, announced that the Board of Directors of the ExportImport Bank of the United States (EXIM Bank) has approved an equipment finance loan of $11 million. Subject to the completion and execution of definitive documentation, this loan will support the significant expansion of IperionX’s advanced titanium manufacturing capabilities.

The EXIM Loan will finance the acquisition of state-of-the-art manufacturing equipment, including advanced Additive Manufacturing systems and precision machining tools. These manufacturing assets will enhance IperionX’s capabilities to produce a broad array of highperformance titanium components, leveraging proprietary and patented

technologies at its Advanced Manufacturing Center in Virginia, USA. This financing initiative is directly aligned with EXIM Bank’s strategic objectives, notably the ‘Make More in America Initiative’ and the China and Transformational Exports Program, which aim to strengthen US manufacturability capabilities, mitigate foreign supply chain vulnerabilities, and bolster economic resilience and national security.

The EXIM Loan provides IperionX with a low-cost, non-dilutive funding pathway to further scale its advanced materials and Additive Manufacturing capabilities, and underpin a fully integrated, end-to-end titanium supply chain within the United States. Titanium is prized for its superior strength-toweight ratio, exceptional corrosion

which is expected to allow for vertical integration of operations and efficient production processes in the future.

The facility is projected to have an initial production capacity of 2,000 metric tonnes annually, with plans to scale to 5,000 metric tonnes. This US$75 million facility was supported by an up to €18.7 million grant from the EU’s Just Transition Fund and a US$50 million credit facility from Export Development Canada, with construction to be completed in 2025.

At its June 2023 groundbreaking, European Commission President Ursula von der Leyen recognised the facility as a significant advancement for Estonia and Europe. The facility is said to represent one of Europe’s – and the world’s – most strategic critical materials projects in rare earth magnetics outside of Asia. The expansion will help Neo meet the growing demand for highperformance magnets in EVs and other applications.

www.neomaterials.com

resistance, and outstanding performance under extreme conditions, making it critical for advanced industries such as aerospace, defence, automotive, and healthcare. Currently, the US is overwhelmingly reliant on foreign sources for primary titanium (sponge) and titanium minerals, creating significant economic and national security vulnerabilities.

Through its Advanced Manufacturing Center, IperionX is utilising its patented technologies to produce high-value titanium products in Virginia, creating highly skilled American manufacturing jobs and addressing critical supply chain gaps. The EXIM Loan directly supports IperionX’s mission to re-shore a low-cost, uninterruptable ‘all-American’ titanium supply chain, essential for both national security and sustained economic growth.

The proposed EXIM Loan remains subject to the agreement and execution of binding documentation. www.iperionx.com

Gasbarre delivers precision compaction systems purpose-built for sintered NdFeB magnet production.

With over 50 years of experience in powdered material compaction, Gasbarre understands the unique demands of rare earth magnet manufacturing— down to the powder behavior, pressing mechanics, and post-process control.

Why Magnet Manufacturers Are Choosing Gasbarre:

Why Magnet Maufacturers Are Choosing

n Proven expertise in mechanical, hydraulic, and servo-electric compaction

Proven expertise in mechanical, hydraulic, and servo-electric compaction

n Deep knowledge of NdFeB powder rheology along with impacts of residual magnetism and force-per-area

Deep knowledge of NdFeB powder rheology along with impacts

n Integrated electromagnetic coil systems in transverse or axial configurations (up to 2.0T field)

Integrated electromagnetic coil systems in transverse or axial

n Tooling designs optimized for magnetic permeability and robustness

n Unique experience in precise inert atmosphere control

Tooling designs optimized for magnetic permeability and robustness

n Fully engineered and built in the USA—including fabrication of components

Fully engineered and built in the USA—including fabrication of components

www.gasbarre.com

Amaero signs $22 million powder supply agreement with Velo3D

Amaero Ltd, based in McDonald, Tennessee, has announced a five-year exclusive supply agreement with Velo3D, headquartered in Fremont, California. As Velo3D’s hardware is manufactured, and software developed, in the US, and its data packets stored by a US-based company, Velo3D is positioned to play a role in the nation’s efforts to reshore advanced manufacturing and accelerate the adoption of Additive Manufacturing.

Based on demand estimates, Amaero’s revenue from C103 and titanium alloy powder sales over the fiveyear agreement is expected to total approximately $22 million, subject to Velo3D’s production demand.

Through the agreement, Amaero will be Velo3D’s exclusive supplier of Niobium C103 and other refractory alloy powders, including molybdenum, tantalum, tungsten, and zirconium alloys, and its preferred supplier of titanium alloy powders.

Velo3D will qualify Amaero’s spherical powders and develop proprietary build parameters exclusively for Amaero’s C103 spherical powders and refractory alloy

Arcast Atomizers are custom built and competitively priced to meet the growing demand to produce high quality, low cost, technically advanced metal powders fulfilling the requirements of today’s pioneering manufacturing processes.

We can supply machines to atomize titanium alloys, super alloys, refractory and reactive metals, and ferrous and non-ferrous alloys in high vacuum purged vessels with inert gas replacement atmospheres.

We have installed machines all over the world, from 1 kg research furnaces to 1000 kg production units.

powders on all Velo3D Sapphire family of AM machines. Velo3D will qualify Amaero’s titanium alloy powder and exclusively develop build parameters for new machine sales. The build parameters will be provided with AM machine licencing at no additional cost to customers.

Velo3D will also exclusively offer Amaero’s C103, refractory and titanium alloy powders for sale to its AM machine customers.

Dr Arun Jeldi, Velo3D’s CEO, commented, “Velo3D is the leading US equipment manufacturer for scalable metal 3D printing technology with integrated hardware and software systems. As the United States undergoes a domestic manufacturing renaissance, it’s imperative that US companies lead on the innovation front, scale manufacturing throughput, and create more resilient supply chains.

“Velo3D is very excited to enter a long-term supply agreement with Amaero and to extend Velo3D’s proprietary print parameters to include C103 and refractory alloy powders. Increasingly complex geometry of parts coupled with iterative design and faster production cycles drive accelerated adoption of metal 3D printing. And, as space and defence applications evolve to require materials that perform in very high temperature and extreme condition environments, a proficient capability to 3D print parts from C103 and refractory alloys is an important and differentiating capability,” he continued.

“Developing print parameters in collaboration with Amaero is important for domestic high-value manufacturing and it’s an important new market for Velo3D. Given the extensive installation of Velo3D Sapphire printers in leading space companies, this is a natural extension of our core capability and will benefit Sapphire printer customers, as well as Rapid Production Solutions customers.

“Amaero’s team has over three decades of pioneering experience in atomisation of refractory and titanium alloy powders and has made forward-leaning capital investment to commission the industry-leading atomisation technology. Amaero has installed the only EIGA Premium technology in the US. With the first atomiser commissioned, a second scheduled to be commissioned in June and a third atomiser to be commissioned next year, Amaero has created the largest and most responsive production capacity for refractory and titanium alloy powders in the United States. Our partnership with Amaero is an important milestone for Velo3D.”

Hank J Holland, Amaero’s chairman and CEO, shared, “The re-shoring, development and scaling of US domestic advanced manufacturing and supply chain capabilities are foundational to Amaero’s corporate strategy. Following three decades of offshoring manufacturing, including capital investment and workforce development, the Trump Administration has established industrial policy as a priority initiative that supports national security and economic policy.”

www.velo3d.com

www.amaeroinc.com

CNPC launches high thermal and electric conductive Al0407 aluminium powder

CNPC Powder, headquartered in Vancouver, Canada, with production facilities in China, has launched CNPC-Al0407, a new aluminium alloy powder for Additive Manufacturing. The alloy is reported to offer high thermal and electrical conductivity, alongside excellent mechanical properties.

The optimised aluminium alloy powder achieves a conductivity exceeding 50% IACS and a thermal conductivity as high as 200 W/m·K. The material is compatible with mainstream Additive Manufacturing technologies, including Laser Beam Powder Bed Fusion (PBF-LB) and Electron Beam Powder Bed Fusion (PBF-EB).

Low oxygen content and high flowability also ensure stable Additive Manufacturing processes, allowing users to achieve part density exceeding 99.5% and reduce post-processing costs.

The powder is produced using CNPC Powder’s proprietary AMP (Automated Metal Production) process. This technology ensures precise control of alloy composition ratios, guaranteeing consistent high performance across all production batches, while significantly enhancing production efficiency.

With high electrical conductivity, the alloy is said to meet requirements for precision circuits, electromagnetic shielding, and conductive connectors. Its high thermal conductivity enables efficient heat dissipation, reduces operating temperatures, enhances

device stability and lifespan, and significantly boosts system performance. Combining excellent thermal performance with the low density of aluminium alloy, CNPC-Al0407 can be used to produce lightweight heat exchangers for aerospace and automotive electronics. It is also ideal for thermally sensitive components such as electronic chip heat sinks and LED cooling modules.

www.cnpcpowder.com

www.ultra-infiltrant.com

Compared to traditional gas atomisation methods such as VIGA (Vacuum Induction Gas Atomisation) and EIGA (Electrode Induction Gas Atomisation), the AMP process reportedly demonstrates higher sphericity and flowability, minimal satellite particles, and optimised AM performance. The process results in over 60% yield in target particle size and supports continuous and efficient production, with shorter cycle times also helping to reduce costs.

Applications

CNPC-Al0407 is intended for use in sectors such as electronics and telecommunications, new energy vehicles, aerospace, and other highend manufacturing sectors.

USA Rare Earth announces $75 million investment in Stillwater magnet manufacturing facility

USA Rare Earth (USAR), Inc, Stillwater, Oklahoma, USA, has entered into a securities purchase agreement with a new fundamental institutional investor to raise $75 million of equity capital via a private investment in public equity (PIPE). The company intends to use the proceeds to fund capital expenditures for its Stillwater magnet manufacturing facility, as well as for working capital and operating expenses.

“We are thrilled by the reception we received from potential investors during our PIPE process,” said Joshua Ballard, CEO. “This sizeable commitment from a single institution allows us to fully fund the capex required for the first phase of our rare earth magnet facility. It comes

at a pivotal moment in USA Rare Earth’s push to build one of the largest domestic sintered rare earth magnet facilities in the country at a time when we as a country most need it. We are on a mission to bring domestic rare earth magnets back to the United States defence, consumer, technology, and industrial sectors. We are now one step closer to achieving our goal.”

Under the terms of the securities purchase agreement, the company will issue – for an aggregate purchase price of $75 million – an aggregate of approximately 8.55 million shares of common stock (the issued shares), pre-funded warrants to purchase an aggregate of approximately 2.16 million shares

USAR’s rare earth sintered neo magnet manufacturing facility in Stillwater is expected to go commercial in the first half of 2026 (Courtesy USA Rare Earth)

Fredrik Johansson appointed as new CEO of MTC Powder Solutions

MTC Powder Solutions (MTC PS), Surahammar, Sweden, has announced that Fredrik Johansson has assumed the role of Chief Executive Officer. Johansson succeeds Magnus Nyström, who will transition to the role of Vice Chairman of the Board and continue to contribute to the company’s strategic direction. Johansson has been with MTC PS since 2011 and has held multiple roles across the organisation. Most recently serving as Technical

Manager, Fredrik has developed a deep understanding of its business and operations. Over the past fourteen years, he has demonstrated strong leadership, technical expertise, and a commitment to the company’s development. His broad experience across departments is expected to provide perspective as he leads MTC PS into its next chapter.

MTC Powder Solutions is confident that Johansson will build on the solid

of common stock and warrants to purchase shares of common stock, in an amount equal to 100% of the aggregate shares at a strike price of $7.00 per share, with an expiry date of six years from the issue date of the PIPE warrants. The shares and the PIPE warrant shares are entitled to customary resale registration rights.

USA Rare Earth, Inc will hold a special meeting of stockholders to approve the issuance of the warrant shares. Stockholders holding a majority of voting power of the outstanding securities of the company have executed stockholder support agreements to vote their shares in favour of such issuance. The closing of the PIPE also is subject to other customary closing conditions for financing of this nature.

USAR is working to build a vertically integrated, domestic rare earth magnet production supply chain. The company is currently constructing a 94,488 m 2 rare earth sintered neo magnet manufacturing facility in Stillwater. It is expected to go commercial in the first half of 2026.

USAR also controls mining rights to the Round Top Mountain rare earth and critical minerals deposit in West Texas, which contains deposits of heavy rare earths such as dysprosium and terbium, as well as gallium, beryllium, lithium and other critical tech minerals.

www.usare.com

foundation in place and continue driving its strategic goals forward. His focus will be on innovation, customer satisfaction, and sustainable growth, with an emphasis on strengthening its capabilities and pursuing new opportunities.

MTC PS thanks Nyström for his leadership during his time as CEO. During his tenure, MTC PS achieved important milestones, and he will continue to be involved in his new role on the Board. His ongoing support will help ensure a smooth transition and continuity for the company’s future development.

www.mtcpowdersolutions.com

Equispheres to establish North American production of APWORKS’ Scalmalloy aluminium alloy

Equispheres, Inc, based in Ottawa, Ontario, Canada, and APWORKS, headquartered in Taufkirchen, Germany, have announced their collaboration on the development of North American production capacity for APWORKS’ Scalmalloy powder, a proprietary high-strength aluminium alloy designed specifically for Additive Manufacturing.

The two companies have entered into a non-binding understanding and are currently exploring avenues for future production, distribution, and technical alignment. They stated that further details will be shared as discussions progress.

Scalmalloy is a patented aluminium-magnesium-scandium alloy developed by APWORKS, a subsidiary of Airbus. The alloy offers mechanical properties comparable to 7000-series aluminium and is engineered for optimal performance in metal AM. Scalmalloy is currently licenced to producers in Europe and Asia, but Equispheres will be the first to establish a North American supply chain, using primarily locally sourced raw materials.

“Scalmalloy will be a great addition to our line of high-performance materials for serial AM,” stated

Epson Atmix establishes European sales office to expand metal powder business

Epson Atmix Corporation, a group company of Seiko Epson Corporation based in Aomori, Japan, has partnered with Epson Europe Electronics GmbH to establish a sales office in Munich, Germany. The new office, which opened on April 1, 2025, is expected to strengthen and

Kevin Nicholds, CEO of Equispheres. “We’re excited to be in discussions with APWORKS about producing this high-strength alloy for aluminium parts. North American supply of critical materials such as aluminiumscandium alloys is a key step toward securing the aerospace supply chain.”

Combining high strength with superior ductility and excellent processability, Scalmalloy is widely used in critical, highly loaded components across aerospace, defence, and motorsport industries.

“Equispheres is a logical choice for expanding Scalmalloy production into North America,” said Jonathan Meyer, CEO of APWORKS. “They are widely regarded for their expertise in producing high-quality aluminium powders for Additive Manufacturing, and their access to domestic sources of aluminium and scandium is an important factor in supply chain resilience in an increasingly uncertain world.”

“Scalmalloy powder made in Equispheres’ North American facility will eliminate many of the adoption barriers that have historically limited the use of this alloy in critical programmes,” added Evan Butler-

expand the group’s metal powder business in Europe.

Epson Atmix is a leading producer of high-quality water-atomised spherical metal powders, suited to both Metal Injection Moulding and metal Additive Manufacturing. The company’s range includes iron-based, nickel-based, and cobalt-based alloy powders.

Parts made using its powder can be found in electronic and automotive components, medical devices and more.

Prior to the new sales office, Epson Atmix had been serving the European market directly from Japan. The Munich office will enhance the

Equispheres will provide a secure North American supply chain for Scalmalloy powder optimised for Additive Manufacturing (Courtesy Equispheres)

Jones, Vice-President of Product & Strategy at Equispheres. “By combining the excellent properties of Scalmalloy with our proprietary powder technology, we can deliver an ideal material solution for the most demanding AM applications.” Equispheres produces optimised aluminium powders that have repeatedly demonstrated the capability to enhance the performance of metal AM processes, supporting faster production, better mechanical properties, and more reliable parts. It also produces aluminium alloy powders from standard alloys, which are said to achieve faster build rates compared with traditional powders, with no adverse effects on mechanical properties.

www.equispheres.com

www.apworks.de

Parts made using Epson Atmix’s powder can be found in numerous applications (Courtesy Epson Atmix)

sales and service functions, enabling quicker response times to enquiries from across Europe.

www.atmix.co.jp www.epson-electronics.de

Optimize Your Powder Production for Additive Manufacturing

Linde gases for improved quality and morphology of powder metals

In gas atomization metal powder production, the gas atmosphere impacts particle size and uniformity — so the variables that contribute to your atmosphere system are critical to the final composition of your powder.

Linde helps you control the atomization environment to achieve the best possible powder quality. We offer high-purity argon, nitrogen, and hydrogen to create the ideal conditions, minimize oxidation, and ensure uniform particles. Our technical experts work with you to optimize the composition for your product lines and balance the flows for cost-effective, consistent results.

For total capabilities from a single source, contact Linde.

Visit www.lindeus.com/powders or call 1.844.44LINDE

Making our world more productive

Miba reports stable 2024/25 fiscal year with increased investment in R&D

Miba AG, headquartered in Laakirchen, Austria, has reported a stable 2024/2025 fiscal year, despite a challenging industrial environment. For its financial year, ending January 31, 2025, the company recorded revenue of €1.187 billion, only slightly down from €1.205 billion in 2023/2024.

“Miba is very broadly positioned and active in a wide variety of markets. In the past fiscal year, we generated 61% of our sales with a broad range of Miba products for the industrial goods market and 39% in the automotive sector,” explained F Peter Mitterbauer, Miba CEO. “This reduces our dependence on developments in individual areas and makes it possible to compensate for declines in certain markets through growth in others. In addition, with ‘Technologies for a cleaner planet’, we have had a corporate mission since 2013 that creates real added value for our customers. With Miba technologies, we are helping to reduce the carbon footprint of our customers’ products.”

RevolutionaRy

Clean energy

Miba generated around €200 million in sales with technologies for the generation and transmission of clean energy, around 17% of its total sales. Growth is said to be particularly strong with products for wind energy, where Miba’s sales have more than quadrupled in the past three years.

Most notably, the business with bearings for gearboxes in wind turbines and the production of machines for the construction of huge offshore wind towers are said to be strong growth drivers. Miba technology is also used in electronics and in wind turbine brakes. In addition, the company works in hydropower and with technologies for the efficient and low-loss transmission of energy in power grids.

Transportation

Miba’s product sales in the marine industry have doubled over the past three years, while those for railways and aircraft have each grown by more than 50%. The growth driver in the automotive business is e-mobility, where Miba’s sales have more than tripled over the past three years. In particular, high-tech resistors and battery technologies for electric vehicles are said to be key.

“We started developing our product portfolio for e-mobility at a very early stage so that we can provide our customers with the best possible support in the technological transformation of the automotive industry,” stated Mitterbauer.

High investments in the future

While the company noted the 2024/2025 fiscal year as challenging, Miba further increased investments to €138 million, up from €130 million in 2023/2024. It stated that €84 million was invested in property, plants, and equipment; over €2 million went to training and further education. The largest increase was in research and development investments, which rose by more than 20% to €52 million compared to the previous financial year – a ratio of 4.4%.

“All of this underlines our commitment to developing the highly innovative products of tomorrow together and in close partnership with our customers,” added Mitterbauer.

According to figures from the Austrian Patent Office, the Miba Group registered twenty-nine new patents and utility models in 2024, making it the patent leader in Upper Austria and among the top five companies in wider Austria.

Financial independence and stability

Miba’s high equity ratio increased further in the past fiscal year to 58.3%, against 53.8% in the previous fiscal year.

“Miba’s financial independence and stability create the basis for our company’s future investments. These investments enable us to develop and produce sustainable products with an ever smaller carbon footprint together with our customers. This is how we want to build markets and grow successfully in close partnership with them,” concluded Mitterbauer.

www.miba.com

CPMT releases free-toaccess Ferrous PM Sintering Troubleshooting Guide

The Center for Powder Metallurgy Technology (CPMT) has published its Ferrous Powder Metallurgy Sintering Troubleshooting Guide. The guide is designed to assist PM parts manufacturers in troubleshooting common sintering issues specific to ferrous PM components.

Key features of the guide include:

• Safety guidelines: Useful guidelines for the safe operation of atmosphere furnaces.

• Common furnace testing procedures: Step-by-step methods to assess furnace conditions and identify potential problems.

• Sintering conditions: Insight into common sintering conditions, including typical failures and practical solutions.

• Furnace belt life: Examples of common concerns that may degrade furnace belt life, with suggested solutions to enhance longevity.

The guide aims to assist teams in overcoming sintering challenges, making it a valuable tool for enabling sintering processes and optimising furnace operations. www.cpmtweb.org

Change of Executive Director at JPMA

Yoshio Uetsuki, Executive Director of Japan Powder Metallurgy Association (JPMA), has announced his retirement, effective May 23, 2025. Tetsuya Sawayama, formally of Kobe Steel and a JPMA board member, was announced as the new JPMA Executive Director.

“I would like to express my deepest gratitude for the exceptional support received during my term in office,” Uetsuki stated. “I will treasure all the happy memories I shared with you all.” www.jpma.gr.jp

• Simple, quick set-up

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• Increased productivity Upper punch with Macro

with Matrix

www.system3r.com Lower punch with Macro Core rod

Following Yoshio Uetsuki’s (left) retirement, Tetsuya Sawayama (right) will become JPMA Executive Director (Courtesy JPMA)

Valimet to atomise APWORKS’ Scalmalloy powders in the United States

Valimet, headquartered in Stockton, California, USA, reports it has entered into a non-binding agreement with APWORKS to atomise Scalmalloy powder in the United States. The high-strength aluminium alloy powder, developed for Additive Manufacturing, is wellsuited to a wide range of aerospace and defence applications.

“In 2024, we were awarded a Phase I SBIR grant by the Defense Logistics Agency to support the atomisation of scandium–aluminium powders. It makes perfect sense that we have this type of conversation with APWORKS,” stated Luigi

Alzati, Valimet VP – Sales and Marketing.

“We’re grateful to Jonathan Meyer, CEO, and the team at APWORKS for their trust in Valimet’s capabilities. We’re united in our commitment to establishing a US-based supply chain for Scalmalloy AM parts, for the benefit of aerospace and defence applications,” added Alzati.

Scalmalloy is claimed to be the only AM processable alloy that can effectively substitute highstrength 7000 series aluminium alloys from plate or forging. Thanks to its low density, Scal -

USA Rare Earth completes merger with IPXX, secures $50M to boost US rare earth magnet production

USA Rare Earth, LLC, (USARE), based in Stillwater, Oklahoma, USA, has completed its formal business combination with Inflection Point Acquisition Corp.II (IPXX), a special purpose acquisition company. USARE and IPXX also announced an additional $8 million contributed by affiliates of IPXX and other investors, bringing the total investment of IPXX’s affiliates and other investors to nearly $50 million.

USARE’s goal is to build a domestic rare earth magnet supply chain from mine to magnet. It is reported to have a unique opportunity to become the leading domestic supplier of rare earth neo magnets and heavy rare earths required for technologies across a wide range of industries, including semiconductors, defence, robotics, electric vehicles and energy transition.

Joshua Ballard, USA Rare Earth’s CEO, shared, “The recent news on tariffs and rising global geopolitical tensions are a wake-up

call for America – we must build a domestic rare earth mineral and magnet supply chain here at home to support a wide range of critical technologies, including our national defence.”

“I’m incredibly proud of this team as the closing of this transaction and our listing on Nasdaq is another key milestone in our evolution in building this supply chain. The additional capital raised will help propel us forward as we build one of the largest magnet facilities in North America to serve the wider neo magnet market, as well as develop our incredibly unique deposit at Round Top that, in my opinion, is a strategic national asset,” Ballard continued.

Michael Blitzer, CEO of IPXX, added, “The public listing of USA Rare Earth marks a significant milestone for our company, our customers, and US national security. The company’s strategic vision to return the USA to domestic rare earth magnetic

Scalmalloy is used in highly loaded and safety-critical parts. Seen here is a fluid-integrated engine thrust frame demonstrator built for ArianeGroup (Courtesy APWORKS)

malloy provides density-specific properties that are said to be extremely competitive, even with the highest-strength alternatives. www.valimet.com www.apworks.de

production is now one step closer. We look forward to working closely with our experienced management team and shareholder and government constituents to build a strategic national asset.”

USA Rare Earth is currently building the first phase of its neo magnet facility in Stillwater, Oklahoma, which is expected to be operational in early 2026. This first phase is targeting a production capacity of 1,200 metric tons per annum (tpa) and will serve a diverse set of customers and industries. The company plans to expand capacity to nearly 5,000 tpa in future phases, to become one of the largest manufacturers in North America. USARE intends to ultimately supply its magnet production from its control of the mining rights to the Round Top Mountain deposit in West Texas.

Round Top is an above-ground mineral deposit containing at least fifteen of the seventeen rare earth elements, plus gallium, beryllium and other critical tech minerals. The company has successfully piloted proprietary rare earth separation technology, which it plans to deploy once mining at Round Top begins.

www.usare.com

Outokumpu announces stainless steel powder for aerospace and aviation AM applications

Having entered the metal powder market for Additive Manufacturing in 2023, Outokumpu, headquartered in Helsinki, Finland, reports that it is now expanding its range to include metal powders for the aerospace and aviation sectors. The company has already delivered the first batch of a new stainless steel powder grade for a unique aerospace application.

The spherical stainless steel powder is refined with specific alloy additives to make it a high-performance austenitic stainless steel powder. The solution is intended as an alternative to nickel-based alloys in highly demanding Additive Manufacturing applications and has been developed to meet customer demand for components in small quantities and with shorter development cycles.

To demonstrate its capabilities, a jointly engineered heat exchanger component has been developed for the aerospace sector, subject to prototype validation. This is said to support the company’s primary focus on producing metal powders that are not yet on the market and are suitable for producing parts for demanding applications.

“Outokumpu is committed to accelerating circular business models for high-tech stainless steel applications,” stated Marten Franz, Head of Metal Powder Business at Outokumpu. “Our go-to-market strategy is to innovate product designs for complex, high-performance geometries for niche applications. While we focus on our expertise in creating new

recipes for metal powders, we rely on our ecosystem of 3D printing engineering partners to create endproducts according to customer specifications. We are excited to enter the aerospace and aviation industry with our powder solutions.”

Besides producing stainless steel for Additive Manufacturing aerospace and aviation applications, Outokumpu hopes to develop new powder grades to serve a variety of sectors.

“We have been ideating medicalgrade powder specifications for the health-tech applications, dedicated to the development of nickel-free materials. Such material grade can also be used in jewellery, such as nickel-free stainless steel earrings or watches. In addition, Outokumpu is working on developing heat-resistant alloys for additively manufactured components such as turbines or for use in power plants,” explained Franz. www.outokumpu.com

HC Starck Tungsten receives €60M funding for battery black mass recycling

HC Starck Tungsten, based in Goslar, Germany, has announced that it is set to receive €60 million in funding from the German federal government and the state government of Lower Saxony to support the recycling of battery black mass, which consists of the ground-up components of used lithium-ion batteries after the casing has been removed.

The company’s recycling process, for which six patent applications have been filed, is said to achieve a significantly better raw material yield compared to established methods, while consuming considerably fewer auxiliary materials and energy. It also produces only a tenth of the CO 2 emissions that would be generated by mining primary lithium, nickel, cobalt and manganese.

“This comprehensive funding commitment is an important step towards the industrial use of our innovative technology for the recycling of black mass,” stated Dr Hady Seyeda, CEO of HC Starck Tungsten. “We are delighted that the federal and state governments are supporting the implementation of our concept in such a concrete way.”

For an industrial-scale application, HC Starck Tungsten is

considering the construction of a plant in the Oker Metallurgical Park with an investment volume of around €340 million. The corresponding funding application was also supported by parent company Mitsubishi Materials Corporation. If the project steps go according to plan, the two-year construction work could begin in the first half of 2027. The target recycling capacity is around 20,000 tons of black mass per year, comparable to the battery content of around 100,000 small electric cars.

Regional, national and European sustainability

The funds – 70% of which are being provided by the Federal Ministry for Economic Affairs and Climate Protection and 30% by the state of Lower Saxony – are being awarded as part of the EU directive on the ‘resilience and sustainability of the battery cell production ecosystem.’ The investment is expected to help establish and expand production capacities along the battery value chain in Germany and the European Union, secure employment and value creation in Germany and ultimately enable climate-friendly mass production of sustainably produced battery cells in Europe.

Tekna appoints semiconductor industry veteran Claude Jean as new CEO

Tekna Holding ASA, Sherbrooke, Quebec, Canada, has announced that Claude Jean has been appointed as the new CEO of the Tekna Group, effective April 28, 2025.

Jean is an accomplished senior technology executive with a proven track record of building and leading world-class electronic manufacturing services and R&D. He joins Tekna from Teledyne Technologies where he has held several leading positions including Executive Vice President,

Strategy & Partnership, Semiconductor and as General Manager of Teledyne DALSA, an international leader in high-performance digital imaging and semiconductors.

“It is an honour for me, and I am excited to take over as CEO of this impressive high-tech company,” Jean stated. “Together with the highly competent Tekna team I am looking forward to executing on its strategy and growth plan to increase value for our customers and shareholders.”

Lower Saxony’s Economics Minister Olaf Lie and HC Starck Tunsten CEO Dr Hady Seyeda (Courtesy HC Starck Tungsten)

At regional level, the funding decision is hoped to strengthen Goslar’s position as a locale for innovation, business, and production, to mitigate the negative effects of structural change and to promote the operation of particularly sustainable industrial plants.

Lower Saxony’s Economics Minister Olaf Lies explained, “Southern Lower Saxony and Goslar in particular have a strong tradition in ore mining and metal processing. The state of Lower Saxony has long been supporting the region in becoming internationally competitive in the field of recycling and optimising the value chains in the recycling of lithium-ion batteries. The funding of HC Starck Tungsten is a milestone for the environmentally friendly recycling of black mass on an industrial scale and thus makes an important contribution to securing raw materials and safeguarding industrial jobs.” www.hcstarck.com

Jean replaces Luc Dionne, who is stepping down from the role. “The Board would like to thank current CEO Luc Dionne for leading Tekna through a period of strategic growth in a very dynamic era for the Additive Manufacturing industry. Since 2014, Tekna has grown its strong plasma technology foundations to a leading provider of advanced materials and plasma solutions to several industries – serving the most demanding customers within aerospace, defence, medical and microelectronics,” stated Dag Teigland, Chair of the Board of Tekna Holding ASA. www.tekna.com

Rosswag invests in qualloy’s metal powder marketplace

qualloy, based in Düsseldorf, Germany, an intermediary for buyers and sellers in the metal powder market, has secured Series Seed funding from Additive Manufacturing service provider Rosswag Engineering, headquartered in Pfinztal. The company has stated that the strategic investment strengthens its position as a trusted sourcing platform while enabling it to expand its business.

Using an intelligent search algorithm, qualloy enables users to find well-suited metal powders for their specific machines and specifications from a broad range of certified global suppliers. This marketplace allows users to freely switch between different powder manufacturers, optimising price, delivery time, and quality, while enabling a transparent and efficient procurement process.

Building on its existing marketplace for metal powder sourcing, qualloy also plans to expand its business in the coming months with its own line of internationally sourced powders that are Rosswagqualified. Customers will be able to purchase the powders through qualloy’s procurement processes, backed by local support representatives.

Dr-Ing Gregor Graf, Head of Technology at Rosswag, commented, “Platforms and online marketplaces hold tremendous potential in the B2B sector, enabling effective procurement and streamlined processes. Together with qualloy, we are creating the perfect partnership to offer an unmatched price-quality ratio for metal powders to drive the upcoming AM market growth.”

Bodycote achieves SBTi validation for its enhanced carbon reduction target, commits to 46% emissions cut by 2030

Bodycote plc, headquartered in Macclesfield, Cheshire, UK, has announced that the Science Based Targets initiative (SBTi) has officially validated its upgraded science-based carbon reduction target. This milestone is said to highlight Bodycote’s commitment to taking decisive action against climate change and driving efficiency across its global operations.

In 2022, the company became the first major heat treatment company to set a science-based carbon reduction target. The upgraded target builds on Bodycote’s earlier success in reducing its energy use and carbon emissions, committing to a 46% reduction in Scope 1 and 2 emissions by 2030 compared to a 2019 baseline. This new goal marks a major step forward from the previous target of a 28% reduction

by 2030, which was achieved six years early in 2024.

Bodycote provides advanced material solutions that address complex challenges, supporting customers in cutting emissions and achieving their decarbonisation targets. For instance, outsourcing heat treatment to Bodycote using a low-carbon thermal processing technology enabled a customer to lower carbon emissions by up to 90% per part, while also enhancing product performance.

Lily Heinemann, Chief Sustainability Officer at Bodycote, remarked, “Achieving SBTi validation for our enhanced target reflects our enduring commitment to sustainability and the measurable progress we’ve made. By exceeding our previous goal ahead of schedule and setting ourselves

“With Rosswag, we have found the perfect partner to take qualloy to the next level. Their knowledge, network, and infrastructure are an ideal match for our vision of revolutionising metal powder procurement. We look forward to the exciting opportunities ahead,” Yannik Wilkens, CEO and co-founder of qualloy, stated.

www.rosswag-engineering.com www.qualloy.com

this higher bar, we’re demonstrating that bold climate action is both achievable and essential. We are excited to continue leading efforts to make a meaningful impact on the global climate challenge and support our customers to achieve their goals.”

Over the last three years, Bodycote has achieved a 29% reduction in Scope 1 and 2 emissions, positioning itself strongly to meet the ambitious 46.2% reduction goal by 2030. In 2024, Bodycote launched a new integrated strategy that aligns its business objectives with long-term sustainability commitments. With clear objectives extending to 2030 and beyond, the group is delivering measurable environmental and social impact across all stakeholders. This commitment is further reflected in its strong performance in key ESG ratings, including an A-leadership rating for CDP Climate in 2024 and an AA rating from MSCI. www.sciencebasedtargets.org www.bodycote.com

Goodfellow expands materials testing capabilities with acquisition of BAS and Suisse Technology Partners

Goodfellow, a specialist metals and material supplier based in Huntingdon, UK, has acquired both the UK-based Bureau of Analysed Samples (BAS) and Switzerland’s Suisse Technology Partners (STP) in two deals that will give it access to state-of-the-art laboratories, testing facilities, and an unrivalled Certified Reference Materials (CRM) capability.

These transactions will position the business as a critical partner to research and industry through its ability to offer over 170,000 different materials and access to customisation, certification, fabrication, and full testing services.

They follow Goodfellow’s acquisition of Potomac Photonics last year, supporting the firm’s ambitious

growth targets of over £50 million in revenue within the next two years.

“We set out at the start of this year our desire to achieve growth through an increase in organic sales and several key acquisitions – these first two are strategically important purchases for setting our future direction,” explained Simon Kenney, CEO of Goodfellow. “BAS has been one of the leading figures in Certified Reference Materials (ISO:17034 and ISO/IEC:17025) for decades and these CRMs play a vital role in the development of new products in electronics and technology, renewable energy, automotive, defence and healthcare.”

“Suisse TP complements this deal perfectly. It is extremely well respected in the global R&D scene and its certified laboratories and

Goodfellow’s CEO, Simon Kenney, and CFO, Andrew Watson (Courtesy Goodfellow)

expertise in surface technology bridges the gap between material supply and application testing,” Kenney continued.

“We are constantly looking to add further value to our global customer base and these acquisitions do exactly that, adding Certified Reference Materials to our range and additional material testing capability,” Kenney concluded. “There are other acquisitions in the pipeline, with discussions progressing well across multiple fronts.”

www.goodfellow.com

EU Parliament relaxes car emissions rules with automakers given extended compliance period for CO2 targets

European automakers will have longer to comply with the regions CO 2 emissions targets for cars and vans following the European Parliament’s decision in May 2025 to back a softening of the rules. This also included the potential reduction of fines for automakers.

According to Reuters, European manufacturers have warned that enforcing the targets this year could have resulted in fines of up to €15 billion, given that the goals rely on selling more electric vehicles, a segment in which they lag behind Chinese and US rivals.

Following heavy lobbying, the European Commission proposed allowing automakers to meet the

targets based on their average emissions over the period 20252027, rather than just this year. EU lawmakers voted 458 to 101 in favour of the change, with fourteen abstentions.

The European Commission also wants to ‘slash red tape’ in its energy policies, according to draft conclusions for a summit of EU energy ministers next month, reportedly seen by Reuters . The draft conclusions backed the plans to simplify more EU laws, and said this “is expected to have a profound impact on lowering the regulatory burden for companies in the energy sector and energy-intensive industries while maintaining alignment

Oerlikon launches MetcoMed brand with metal powders for medical Additive Manufacturing applications

Oerlikon Metco, headquartered in Winterthur, Switzerland, has launched its new MetcoMed brand with the release of two materials tailored for the Additive Manufacturing of medical components and implants. The new metal powders, MetcoMed Ti64 G23-C, a titanium alloy, and MetcoMed CoCrMo F75-A, a cobalt-chromium alloy, are now available through the company’s distribution network.

MetcoMed Ti64 G23-C

Building on the established and industry-approved alloy for Additive Manufacturing, Oerlikon’s MetcoMed Ti64 G23-C is said to provide high load-bearing capacity, good ductility, excellent biocompatibility, and good corrosion resistance.

The material reportedly offers a tensile strength of over 1,000 MPa at 10% elongation. It has been optimised for Laser Beam Powder Bed

with the original policy objectives.”

Reactions to the EU’s simplification efforts have been mixed, it was stated. Some industries have backed the plans as a boost to their competitiveness, while large companies said they offered little relief from bureaucracy, and some investors and campaigners criticised the weakening of sustainability rules as a blow to Europe’s efforts to curb climate change.

European Commission President Ursula von der Leyen has said the change would give European automakers “breathing space”. Volkswagen said last week that the longer compliance period would still pose a burden in 2025.

Critics argue that the auto industry has had seven years to prepare for the 2025 targets and that the €15 billion estimate for fines is vastly inflated.

www.europarl.europa.eu

Fusion (PBF-LB) Additive Manufacturing technology and can function as a direct drop-in solution for most machine brands.

MetcoMed CoCrMo F75-A

Cobalt-chromium alloys are widely used for various orthopaedic and dental implants, with CoCrMo one of the most-used alloys for tooth implants and total hip replacement due to its superior corrosion qualities, antibacterial properties, improved cell adhesion, and potential for reducing inflammation markers.

Oerlikon has developed and launched a CoCrMo material specifically for PBF-LB Additive Manufacturing, noting the material’s high strength, ductility, and biocompatibility. MetcoMed CoCrMo F75-A provides a reported tensile strength of 1,050 MPa and 35% elongation despite its low carbon content (desirable for an implant material). The powder exhibits a particle size distribution that enables its use on most PBF-LB AM platforms.

www.oerlikon.com/metco

Additively manufactured titanium knee tip base (left) and titanium hip implant (Courtesy Oerlikon Metco)

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Plansee receives NSG Group sustainability award for molybdenum glass melting electrodes

The NSG Group, headquartered in Tokyo, Japan, is a global manufacturer of glass and glazing products for buildings, the automotive industry, and technical applications. The company has honoured Plansee with a sustainability award, recognising it as one of the best-performing suppliers in NSG’s annual benchmark.

“We are proud of this award and appreciate the recognition of our consistently pursued sustainability strategy,” said Oliver Bridger, Head of Sales in the UK. “The award is a testament to the hard work and dedication of our entire team.”

Plansee has been supplying the NSG Group with molybdenum glass melting electrodes for a number of years. These electrodes, used in

electrically heated glass tanks, must be able to withstand extreme thermal loads and aggressive glass melts.

In Europe in particular, the glass industry is under pressure to become more sustainable, as glass production is an energyintensive process. Conventional glass furnaces are heated mainly with fossil fuels, however, European climate legislation is driving a trend towards more electric heating in the glass industry. This technology uses molybdenum glass melting electrodes, a core product of Plansee.

As a key supplier to the glass industry, Plansee aims to contribute to technological change and thus to more sustainable glass production

European project finds virgin REE alternatives for permanent motors

The Sustainable Recovery, Reprocessing and Reuse of Rare-Earth Magnets in a European Circular Economy project, established in 2019, is evaluating rare earth elements (REEs) for new motors and developing designs to improve the recyclability of electric motors.

As EVs gain popularity, increased REEs are required to create their permanent magnet synchronous motors (PSMS), where the rotor has magnets embedded that are attracted to a rotating magnetic field using the battery’s power.

The recycling process

Because of the nature of the material, magnets can be difficult to separate from the rotor, breaking up into magnetised powder that sticks to ferrous scrap. Through the use of the newly developed hydrogen processing of magnet scrap (HPMS) – developed at Birmingham University – produces a non-magnetic,

reusable powder without removing magnets from the rotor first.

The resultant rare earth-rich powder can then be reprocessed into new magnets, avoiding traditional energy-intensive methods. This means that the energy used to produce magnets is 12% of that needed to make them from virgin material.

Project member ZF, Friedrichshafen, Germany, has built and tested motors made using HPMS and reported that the performance of the magnets was almost identical to those manufactured using freshly mined materials.

Permanent magnet alternatives

Beyond recycling, the use of virgin REEs is can also be reduced by transitioning away from permanent magnets entirely. Externally (or separately) excited synchronous motors can replace the permanent magnets in rotors with electromagnetic

Plansee has been supplying the NSG Group with molybdenum glass melting electrodes for a number of years (Courtesy Plansee)

through innovative product development.

Plansee offers a varied selection of components, from melting electrodes, tank reinforcements and tank reinforcement components to stirrers and spinning nozzles. The company’s products made from molybdenum and tungsten powder are designed to maximise the efficiency and durability of glass production systems and to optimise production processes.

www.nsg.com www.plansee.com

SUSMAGPRO is working to develop alternatives to the use of virgin REEs in magnets (Courtesy SUSMAGPRO)

windings. These have been used by Renault since the launch of the Zoe supermini electric car in 2012. Feeding an electric current from the outside of the motor into the rotating core, however, involves the use of brushes so the motor isn’t ‘brushless’ like a PMSM. An alternative that avoids the use of brushes is ZF’s I2SM (in-rotor inductive excited synchronous motor). This has a small electronic generator called an inductive exciter, uniquely fitting inside the rotor shaft rather than on the end, which makes the motor longer.

www.susmagpro.eu

Adeline Riou replaces Ralf Carlström as EPMA President

The European Powder Metallurgy Association (EPMA) has appointed Adeline Riou as its new president. Riou, who serves as Market Development Director – Metal Powders at Aubert & Duval, France, succeeds Ralf Carlström of Höganäs AB, Sweden, who is stepping down after six years as the association’s president. The EPMA also announced Steven Moseley, Chief Scientist Hard Materials & Key Expert at Hilti, as its new Treasurer.

The appointments were confirmed during the association’s General Assembly. Every three years, the EPMA Statutes require members to elect a new president and treasurer, both subject to a maximum of two terms.

“I’m very pleased that Adeline accepted the appointment as President of EPMA,” stated Carlström.

“Her long experience within the Powder Metallurgy field, combined with her dedication, will be a very valuable asset for EPMA in the future.”

Riou has worked in the field of metal powders for close to thirty years, having been at Aubert & Duval since 2018 and at Erasteel for twenty-two years. Over that time, she has been very active within EPMA, where she initiated the EuroHIP sectoral group in 2009 and the EuroAM sectoral group in 2013 before joining EPMA Board and Council in 2023.

president, succeeding Ralf Carlström (right) (Courtesy EPMA)

She served as co-chair at the WorldPM2022 Congress and received the EPMA Distinguished Service Award in 2023. Riou is also the co-author of the EPMA’s Introduction to HIP technology and Introduction to AM technology publications.

ADVANCED HEATING base of future technologies

• Combination of different heat treatments in one furnace (Debinding+Sintering)

• High-purity atmosphere over a long operating time

• Same furnace for several materials

• Various size in combination with a very compact design (foot print 1 m x 1.6 m)

• Low installation and unit costs

“I am very happy and deeply honoured to have been elected as EPMA’s new president and even more so as the first woman to hold this position,” added Riou. “Many thanks to Ralf Carlström for the opportunity and for the excellent work and new ideas implemented in the last six years to strengthen the EPMA, in particular to recover from the challenging Covid crisis.”

www.epma.com

Continuum Powders recycles nearly one ton of nickel superalloy scrap per week for Siemens Energy

Continuum Powders, Houston, Texas, USA, announced that it has successfully recycled nearly one ton per week of nickel superalloy scrap from a Siemens Energy facility over the last five months of 2024. The reclaimed superalloy, totalling 16,182 kg, is comprised of rare earth minerals and the next step in the process will be to test the reintegration of these materials into Siemens Energy’s supply chain.

“This milestone reflects our unwavering commitment to innovation and sustainability,” said Rob Higby, CEO of Continuum Powders. “By prioritising efficient recycling and high-quality production, we are helping industry leaders reduce their environmental impact and build supply chain resiliency.”

By transforming waste into

valuable materials through its proprietary Greyhound M2P plasma atomisation process, Continuum Powders is working to eliminate the need for energy-intensive traditional recycling methods, minimise landfill waste, and drive the circular metal economy.

The scrap came from Siemens Energy’s facility in Winston-Salem, North Carolina, where the company services equipment for power generation (e.g. gas turbines, steam turbines, and generators.) Using its Greyhound M2P process, Continuum reverted unused engine components into high-quality, nickel-based metal powders tailored to meet the stringent standards of industries such as aerospace, defence, and energy.

“Our goal is to recycle scrap materials into high-quality metal

California Metals and CNPC Powder partner for sustainable Additive Manufacturing powders

California Metals, Newport Beach, California, USA, and CNPC Powder, headquartered in Vancouver, Canada, have formed a strategic partnership to supply and distribute sustainable Additive Manufacturing powders made from 100% recycled feedstock.

“This partnership represents a significant step forward in creating a more sustainable supply chain for the Additive Manufacturing industry,” said Michael Resl, CEO at California Metals. “By utilising 100% recycled feedstock, we’re helping customers reduce their environmental footprint without compromising on quality or performance.”

The collaboration combines California Metals’ experience in environmentally responsible metal solutions with CNPC Powder’s experience in metal powder production.

The partnership will initially result in two 100% recycled products: AlSi10Mg powder for lightweight, high-strength applications and Ti6Al4V powder offering high strength as well as corrosion and fatigue resistance. Both powders are said to have comparable performance to virgin powders, whilst offering a significant reduction in carbon emissions compared to traditional, environmentally costly manufacturing processes. They have already been successfully applied in various sectors (e.g. aerospace, motorsports, consumer electronics and luxury goods), demonstrating their performance and sustainability benefits.

Kathy Liu, president at CNPC Powder, added, “Our combined expertise allows us to deliver powders

powders for reuse in Additive Manufacturing because when we minimise waste and boost circular manufacturing, it makes us a stronger player in the energy sector,” said Rich Voorberg, president of Siemens Energy in North America.

This ongoing partnership aims to establish a new standard for sustainable manufacturing by demonstrating that advanced recycling technology can produce high-performance materials while enhancing supply chains and reducing carbon emissions. The process not only minimises energy consumption, transportation, and material handling but also serves as a cost-effective and environmentally responsible alternative to traditional recycling methods.

“Our recycling and powder production capabilities prove that innovative solutions can deliver significant environmental and economic value while meeting the most demanding industry requirements,” said Michael Brennen, Sales Director at Continuum Powders. www.continuumpowders.com

The partnership will see the production of AlSi10Mg powder and Ti6Al4V powder from 100% recycled feedstock (Courtesy CNPC)

that not only meet but exceed industry standards. Our advanced manufacturing facilities and R&D capabilities, coupled with California Metals’ commitment to sustainability, create a powerful offering for the growing Additive Manufacturing market.”

www.californiametals.com www.cnpcpowder.com

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GranuCharge AL measures electrostatic charges in powders

Granutools, based in Awans, Belgium, has introduced its GranuCharge At Line (AL), an instrument designed to measure electrostatic charges in powders during flow in real time and directly on the production line.

The new GranuCharge AL is designed to measure electrostatic charges in powders (Courtesy Granutools)

Electrostatic charging is a common challenge in powder processing industries such as Additive Manufacturing, and metal powder handling. This phenomenon affects powder flowability, causes handling difficulties, and can even present safety risks.

Unlike traditional lab-based methods, the GranuCharge AL provides instant access to the charge per mass measurement through an integrated load cell combined with a Faraday cup connected to a highly sensitive electrometer. As powder flows through the process and into the device, the GranuCharge AL automatically captures the accumulated electrostatic charge, delivering high-precision results with minimal setup, all without stopping production.

Titomic and Metal Powder Works form strategic partnership to optimise cold spray metal powder

Titomic Limited, based in Brisbane, Australia, has formed a strategic partnership with Metal Powder Works (MPW), based in Clinton, Pennsylvania, USA. The partnership focuses on optimising MPW’s proprietary DirectPowder process for use in Titomic’s Additive Manufacturing solutions, addressing critical applications in aerospace, oil & gas, energy, MRO, and other high-tech industries.

This agreement marks an important step in Titomic’s ongoing efforts to secure and refine high-quality metal powders to complement its cold spray technology. MPW’s Direct Powder process offers a uniquely tunable powder production method, enabling tailored solutions that enhance material performance for demanding industrial applications.

Jim Simpson, CEO & Managing Director of Titomic, stated, “We are

excited to partner and collaborate with best-in-class powder suppliers specific to applications and customer needs. This strategic collaboration with MPW will explore the unique benefits their technology brings to Additive Manufacturing. This aligns with our strategy to secure material sources for our customers across multiple sectors. This agreement is an important step as we continue to cultivate relationships to ensure we maintain a diverse and robust supply chain.”

“Under the Memorandum of Understanding (MOU), Titomic and MPW will conduct joint material testing, performance evaluations, and process optimisations. Upon successful outcomes, the companies will negotiate an offtake agreement to establish future commercial supply arrangements,” Simpson

GranuCharge AL allows users to assess how equipment such as hoppers, feeders, and blenders influence electrostatic charge accumulation to optimise material handling and process design. It also enables users to monitor charge effects on powder spreadability in Powder Bed Fusion machines or during nozzle flow in Directed Energy Deposition (DED), helping to improve powder bed quality and process reliability. Additionally, the GranuCharge AL identifies charge build-up hotspots on production lines in real time, enabling swift corrective actions without interrupting operations.

GranuCharge AL is reportedly the only compact instrument capable of real-time electrostatic charge measurement under true process conditions. This innovation helps industries reduce downtime, optimise materials, and enhance process reliability by providing critical data precisely where it is needed.

www.granutools.com

added. “This partnership will allow Titomic to provide customers with material test results, reducing the amount of time required during the Non-Recurring Engineering (NRE) phase of a contract. The investment increases speed to market and our ability to support our customers while reducing their programme cost and schedule.”

John Barnes, CEO of Metal Powder Works, added, “We’re excited to expand our relationship with Titomic to achieve better results for them and their customers with powder consistency. We have seen in other trials that cold spray users achieve high deposition rates with the DirectPowder™ process aluminium and titanium powders.”

This collaboration is part of Titomic’s broader initiative to expand its US presence and further solidify its role in advanced manufacturing through strategic partnerships, research collaborations, and supply chain diversification.

www.titomic.com www.metalpowderworks.com

Imerys introduces sustainable, catalystfree graphite SU-NERGY

Imerys, Bodio, Switzerland, has introduced SU-NERGY, a sustainable graphite solution said to achieve up to a 60% reduction in CO 2 emissions compared to traditional graphite derived from fossil fuel-based raw materials. From its Bodio facility, the company has been able to transform forest residues into the high-performance material using 100% low-carbon energy sources for production.

SU-NERGY reduces environmental impact and maintains superior performance characteristics whilst addressing the complexities of the European Union (EU) manufacturing supply chain and offering increased sustainability.

“SU-NERGY isn’t just a new product; it’s reshaping the graphite landscape,” said Frank Wittchen,

Vice President & General Manager, Graphite & Carbon Division at Imerys. “By producing in Switzerland using renewable resources, we’re offering a high-performance, customisable solution that reduces environmental impact and mitigates supply-chain risks. We’re not just meeting industry needs – we’re redefining them, paving the way for a cleaner, better future.”

The material’s manufacturing process does not employ a catalyst, reducing potential contamination risks in specific high-purity applications. This resultant purity, combined with its superior electrical and thermal conductivity, makes SU-NERGY versatile enough to meet the evolving needs spanning a wide range of industries, including automotive, energy

storage, electronics, metallurgy, and various other industrial sectors. Additionally, Imerys’s Bodio facility also benefits from nuclear energy certification.

Benefits to European manufacturers In addition to meeting the growing demand for more locally sourced, sustainable materials, SU-NERGY complies with stringent European environmental and quality regulations. This, along with its shorter, reliable supply chain, allows Imerys and its customers to reduce transportation costs and times, thus improving efficiency and lowering the product’s carbon footprint.

SU-NERGY also enhances supply security by reducing reliance on non-EU graphite, mitigating the impact of international trade tensions.

Imerys’ SU-NERGY is now available for sampling. www.imerys.com

ACEA calls for expansion of EV incentive schemes across Europe to meet expected targets

The European Automobile Manufacturers’ Association (ACEA), based in Brussels, Belgium, has published an updated overview of tax and incentive schemes for zero-emission cars and commercial vehicles. As the market for electric vehicles continues to underperform, the ACEA states that the expansion and better coordination of EV incentive schemes at the European level is crucial.

“Today, the EV market share for cars stands at around 15% – that’s still far from where it was expected to be at 25% by the end of this year,” stated Sigrid de Vries, Director General of the European Automobile Manufacturers’ Association (ACEA).

“Europe’s electric vehicle market is still developing and hasn’t hit the crucial tipping point for mass adoption yet. Incentives are one key piece of the puzzle to help drive demand and get us to this common goal.”

While EV technology continues to advance, and there is an increasing range of models priced under €30,000 on the market, upfront costs remain a significant barrier for many consumers. Battery-electric vehicles (BEVs) are currently more expensive than internal combustion engine (ICE) vehicles, largely

due to higher battery manufacturing costs. Therefore, purchase incentives play a crucial role in consumers’ purchasing decisions, making them essential for establishing a mass market for these vehicles.

The withdrawal of incentives for EV purchases in Germany at the end of 2023, leading to the collapse of the German BEV market, highlighted its fragility. As state-funded schemes ended before the market had fully matured, EV purchases dropped by nearly a third.

While the European market is still far from its potential, several purchasing incentive schemes are being phased out. The number of member states not offering any purchase incentives for cars has increased to eight, up from six last year. The availability of schemes for heavy-duty vehicles (HDV), such as trucks and buses, is even more critical, with over a third of member states offering no incentives for acquisition. Only twelve countries offer infrastructure incentives despite the significant lack of public HDV-suitable charging points.

While robust incentive schemes have been proven to work, the issue extends beyond just finan -

William Rowland celebrates 195 years supplying metals and alloys to industry

William Rowland, headquartered in Barnsley, UK, has announced it is celebrating its 195 th anniversary this year, marking almost two centuries in the metals industry. Founded in 1830 by Jonathan Rowland, the company has evolved into a global supplier of metals and alloys, serving a diverse range of sectors including civil aerospace, defence, automotive and EV, energy, Additive Manufacturing, petrochemicals, and electronics.

In addition to its revert alloy and refined metals businesses, William

Rowland is an established supplier of metal powders in different particle sizes, shapes and alloys. The company offers gas-atomised metal powders specifically designed for Additive Manufacturing, including Inconel 625, 713 and 718 nickelbased powders possessing high strength properties and resistance to elevated temperatures. It also offers Hastelloy X, a nickel-based alloy that has exceptional strength and oxidation properties, and F75, a cobalt chrome alloy.

cial incentives to a need for better coordination across European countries. Unlike nations such as China, Europe has a fragmented framework, with schemes being decided at the national level. This results in over thirty widely differing schemes across the continent, with different funding levels and criteria, leading to a multi-speed EV uptake in Europe.

Belgium is known for its generous schemes and higher EV share in the powertrain mix – but this starkly contrasts with weaker schemes in several Central and East European member states, where the share is noticeably low. This is why European automakers were disappointed with the lack of funding for demand incentives so far in the Automotive Active Plan, despite Executive Vice-President Ribera previously announcing a pan-European subsidy scheme that could address imbalances and fragmentation. The ACEA encouraged the European Commission to revisit this proposed initiative as it would provide a much-needed impulse at a critical time in the transition.

The ACEA stressed the need for more robust schemes and a cohesive approach to EV incentives. The fragmented landscape of national schemes not only hinders the potential for broader adoption but also delays progress on reaching CO 2 targets in a challenging environment for manufacturers.

www.acea.auto

With the support of its parent company, AMC Group, William Rowland recently invested in a state-of-the-art headquarters and recycling centre in Tankersley, which has enabled it to expand and diversify its offerings even further.

Recent investments in key plant room equipment are said to have reinforced the company’s commitment to precision, efficiency, and minimising waste. The company is also placing a greater focus on scrap and recycling supply chains, reducing its carbon footprint while recirculating valuable metals back into the industry.

www.william-rowland.com

Alleima adopts thermal spraying technology to support green transition

Alleima, headquartered in Sandviken, Sweden, reports it has invested in new thermal spray technology. The company aims to develop new products in the field of sustainable energy, where, for example, it can be used in the production of electrolysers used for green hydrogen production. The company said it is in dialogue with several customers, with the first prototype of coated material having already been sent for evaluation.

Thermal spraying is an advanced manufacturing method in which material in powder or wire form is melted and sprayed onto a surface to create a coating with specific properties. The technology enables coatings that are crucial for improving products such as electrolysers for the production of green hydrogen. Green

hydrogen – produced by the electrolysis of water using renewable energy – plays a central role in the transition to a carbon-free economy. Thermal spraying enables the development and industrial production of key components in an electrolysis stack.

“This investment is part of the company’s long-term strategy to drive innovation and create sustainable solutions. It is a pilot that will primarily be used for research purposes but will also be used for small-scale production when possible. By using this technology in our manufacturing processes, we can offer advanced materials and components that meet the high demands of hydrogen production. This initially includes the development of components for electrolyser cells, but also other applications that require robust

and durable coatings,” stated Tom Eriksson, Head of Strategic Research at Alleima.

Alleima anticipates that the adoption thermal spray technology will eventually make it possible to develop products that replace expensive material solutions, thus reducing the cost of electrolyser stacks and, in turn, lowering carbon emissions through the increased use of green hydrogen.

One of the advantages of thermal spraying is that it is a fast process and can be used in many different areas, depending on the base material used. Common materials include metals, metal alloys, composites, and ceramics. These coatings can withstand high temperatures and protect components from wear and corrosion, making them ideal for industrial applications. The coatings can also enhance the properties of the component (e.g. friction, electrical conductivity or insulation).

www.alleima.com

Boeing opens Farnborough HiLACC collaboration centre to support advanced aircraft innovation

Boeing has opened its High-Lift Aerodynamics Collaboration Centre (HiLACC) in Farnborough, UK, to provide a dedicated research space for Boeing, industry and academic partners to collaborate, test and analyse future aircraft concepts. The facility will support testing and development for a range of programmes for Boeing’s commercial aeroplanes and derivative aircraft.

“The future of aerospace is made possible, in part, by facilities like HiLACC,” said Maria Laine, president of the Boeing UK, Ireland and Nordic region. “The UK continues to play a pivotal role in the development of aerospace innovations, and we are excited to see how the new technology developed here will support the evolving needs of our customers.”

With around 930 m 2 of space across three floors, HiLACC will act as a dedicated space for Boeing partners to collaborate on aerodynamic testing and aerodynamics research at the nearby Farnborough wind tunnel. The five metre QinetiQ wind tunnel, located next to HiLACC, is one of only three large, lowspeed pressurised wind tunnels in the world and the only one in the UK. It has supported the testing and design for Boeing aeroplanes, including the 787, 777, 747 and the 737 MAX.

“As we look to the future, we know our customers will continue to count on us to deliver breakthrough products that meet the highest levels of safety, quality and performance,” said Jeff Hogan, chief engineer, Airplane Characteristics, Boeing Commercial Airplanes.

“HiLACC supports the work we’ll do today and tomorrow to develop our next generation of aerospace innovations.”

“This is a significant investment from Boeing and a massive vote of confidence in the future of the aerospace and defence industries in this area. It will ensure that Farnborough continues to be at the forefront of aviation research and development, providing hundreds of well-paid jobs and opportunities for local residents,” stated Alex Baker, Aldershot and Farnborough MP, at the centre’s unveiling.

Since 2015, Boeing has invested more than £110 million in the UK, working closely with government, industry and academia to drive forward technologies that support the UK and global aerospace industry.

www.boeing.co.uk

The HiLACC facility is expected to enable Boeing and its collaborators to reduce the time needed to refine an aircraft’s design and test a model of this design in the nearby wind tunnel. High-lift, low-speed wind tunnel testing is important to aircraft development because it assesses how design changes affect take-off and landing performance. Aerodynamic improvements that increase an aircraft’s fuel efficiency must perform well at take-off and landing, as well as at cruise levels.

Waygate debuts high-resolution computed tomography system

Waygate Technologies, a Baker Hughes business based in Hürth, Germany, has introduced its Phoenix Nanotom HR (High Resolution) computed tomography (CT) system. The new system is designed to make advanced X-ray imaging technology accessible to a broader range of users and is reported to be ideal for applications across numerous fields, including Additive Manufacturing, material science, semiconductor and electronics inspection, battery technology research, geoscience, life sciences, and cultural heritage preservation.

As part of the new product introduction, Waygate also announced a

technology collaboration with X-ray equipment supplier Excillum, Kista, Sweden. Through this collaboration, Phoenix Nanotom HR will use a new high-resolution nanofocus X-ray tube supplied by Excillum for high imaging resolution and contrast across the full voltage range (40-160 kV).

“We are excited to present our Phoenix Nanotom HR here at Control 2025 and announce our strategic collaboration with Excillum,” said Ludovic Milosevic, General Manager Radiography Systems at Waygate Technologies. “Leveraging Excillum’s nanofocus source, the new HR version delivers

Waygate Technologies has launched its high-resolution Phoenix Nanotom HR computed tomography system (Courtesy Waygate Technologies)

Seco introduces self-service carbide tool recycling option

Seco Tools, headquartered in Fagersta, Sweden, has introduced a new self-service carbide tool recycling system in an effort to make the recycling process simple, more transparent and efficient. The digitalised buy-back programme, available in a number of its markets, enables customers to easily return used carbide tools and contribute to a circular economy.

The new web-based service, accessible through customers’ My Pages accounts, offers a streamlined approach where users can request price quotes for their used carbide tools, order free recycling containers, book shipments, track orders, monitor CO 2 savings, and receive a sustainability certificate. By recycling used carbide tools, Seco helps reduce reliance on virgin raw materials such as tungsten,

up to five times better resolution than our existing state-of-the-art Nanotom M. That puts it on par with advanced optical magnification scanners – but with a simpler system, faster learning curve, greater flexibility, and at a better price point than comparable solutions.”

With its 300 nm focal spot technology, the Phoenix Nanotom HR is said to enable high geometric sharpness and detail detectability down to 50 nanometres (0.05 microns). It also allows for high contrast in high- and low-absorbing materials within a single image. The company states that high resolutions can be achieved 3-5x faster than with the Nanotom M or optical solutions, thus reducing scan times for samples requiring 120 minutes for 0.5 µm resolution to as little as forty minutes, or from one hour to ten minutes.

The Phoenix Nanotom’s user interface, featuring automated focal spot selection, is designed to increase ease of use. It allows users to explore sub-micron particles, design deviations, manufacturing issues, material flaws, and geometric structures.

In addition, the system is capable of 24/7 operation with a reportedly excellent stability, effectively reducing the need for maintenance work to a quarter of standard industry levels.

www.waygate-tech.com

cobalt, and tantalum. This approach is said to lower energy consumption by 70% and cut CO 2 emissions by 64%.

“We are committed to making carbide recycling easier and more accessible for our customers. This digital transformation enhances efficiency while ensuring we meet our ambitious sustainability goals,” stated Malvina Roci, Circularity Manager at Seco.

This service is already available in several markets, with ongoing expansion planned across Europe, the Americas, and Asia Pacific. www.secotools.com

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Renishaw and Metalpine develop copper-nickel alloy powders for marine applications

Renishaw, headquartered in Wottonunder-Edge, Gloucestershire, UK, has collaborated with Metalpine, based in Graz, Austria, to create coppernickel alloy (CuNi) powders for use in marine applications. It was stated that a major European naval force is set to use the new powder to manufacture replacement parts in-house using Renishaw’s RenAM 500Q Flex Additive Manufacturing machine.

Naval operations in saltwater environments present challenges, with hydraulic components and other essential parts subject to accelerated wear and corrosion. Rather than relying on extensive supply chains, the naval force opted to additively manufacture replacement parts in-house.

CuNi powders form a protective layer on the surface of components, preventing degradation. This makes them highly durable in the challenging marine conditions where parts are constantly exposed to moisture and sea elements. Engineers from Renishaw and Metalpine partnered to develop process parameters tailored to two specific copper-nickel alloys: CuNi 10, a combination of 10% nickel and 90% copper, and CuNi 30, using 30% nickel and 70% copper.

“Metalpine uses a stable and outstandingly efficient process to manufacture high-quality metal powders focused on particles with high sphericity and no pores. So, it is straightforward for us to develop and produce new powders,” Gerald Pöllmann, CEO of Metalpine, shared. “Collaborating with the AM engineers at Renishaw was a great experience. The team quickly shared what they achieved with our powders during their qualification process, enabling us to create and deliver powders that fit the application perfectly.”

With an open-loop powder system, the RenAM 500Q Flex allows for efficient and quick powder swapping, making it ideal for developing and optimising material properties, part designs and process parameters. With the Reduced Build Volume (RBV) accessory fitted, material prove out can be performed with as little as 0.25 litres of powder, with the same processing environment and optics as the full-scale production system.

“Metal powders made with copper are difficult to process with AM. CuNi 10 is a highly reflective material which is resistant to laser energy, whereas CuNi 30, due to its higher nickel content, is easier

MPIF launches University Outreach Program to promote metal powder technologies to engineering students

The Metal Powder Industries Federation’s (MPIF) Industry Development Board has launched a new University Outreach Program to promote metal powder technologies to future engineers.

Over the past eight years, hundreds of students have attended the annual PowderMet and AMPM conferences with grants from the National Science Foundation (NSF),

Center for Powder Metallurgy Technology (CPMT), and MPIF reserves. However, post-conference interviews revealed that while student grant recipients had a good understanding of metal Additive Manufacturing, they had limited knowledge of other metal powder technologies, such as press and sinter, Metal Injection Moulding (MIM), and isostatic pressing.

Renishaw has collaborated with Metalpine to create copper-nickel alloy (CuNi) powders for Additive Manufacturing (Courtesy Renishaw)

to process,” explained Alex Garcia, AM Design and Applications Engineer at Renishaw. “Leveraging Renishaw’s advanced laser melting technology, we conducted extensive experimentation to refine the energy input parameters. We adjusted the RenAM 500Q Flex power, scan speed and hatch distance to optimise the process for manufacturing with these materials.”

“With these precise settings, we have been able to overcome the material’s challenges, ensuring high-quality, durable parts that can withstand harsh marine environments. This optimisation not only enhances part strength and longevity but also ensures consistent results, allowing our naval customer to manufacture parts that perform reliably under tough conditions,” Garcia added.

www.renishaw.com

www.metalpine.at

The Outreach Program provides an opportunity to engage with students in their local educational environment and teach them that there are many ways to consolidate metal powders. As part of this, the MPIF reported that Stephen Madill of Nichols Portland Inc. and Stefan Joens of Elnik Systems, LLC, recently held a Design of Machine Elements class at the University of North Carolina, Charlotte, USA.

Building on this, the Industry Development Board plans to take the Outreach Program to four universities during the autumn term.

www.mpif.org

QuesTek develops nickel superalloy for Stoke Space’s daily-launch reusable rockets

In collaboration with Stoke Space, Kent, Washington, USA, QuesTek Innovations LLC, Evanston, Illinois, has successfully developed a novel nickel-based superalloy designed for Additive Manufacturing and highpressure, high-temperature oxygen environments. The goal was to enable high-performance, fully reusable launch systems at lower costs and with a higher launch frequency. This alloy is regarded as critical for Stoke Space’s Zenith engine, which operates using a full-flow staged combustion cycle, a highefficiency machine that demands materials capable of withstanding extreme combustion environments where conventional alloys would be expected to fail catastrophically. The

alloy has been fully qualified and meets all performance targets.

QuesTek designed the alloy using its ICMD digital materials design and engineering software platform, to which it attributed the rapid optimisation of composition and processing.

“The development of this printable, burn-resistant alloy is an absolute requirement for Stoke Space to achieve its mission of building reusable rockets that fly daily,” said Jason Sebastian, Executive Vice President of QuesTek. “It’s not an overstatement to say that this type of milestone can change the world. Once this hurdle is removed, I don’t see a limit to the growth potential for the space industry.”

Our proven System now in one square meter

Enabling the future of space access

The nickel-based superalloys are suitable for production via Additive Manufacturing, which enables complex geometries and cooling channels that would not be possible with traditional manufacturing methods. Leveraging manufacturability also allows for rapid implementation of design changes without the lengthy lead time and expense of producing new tooling.

Bill Mahoney, Chief Operating Officer at QuesTek, added, “The material compositions commonly used to increase strength often reduce printability and burn resistance.”

“QuesTek technology helps clients find their sweet spot where all three critical properties coexist – something that would take traditional metallurgy approaches decades to develop. We achieved it in just months,” Mahoney concluded.

www.questek.com www.stokespace.com

Filling height up to 100mm

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Possible to integrate fast tool clamping systems

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Hexagon launches MAESTRO coordinate measuring machine for advanced manufacturing precision

The Manufacturing Intelligence division of Hexagon AB has launched MAESTRO, a new coordinate measuring machine (CMM) engineered to meet the rising productivity demands of modern manufacturing and the increasing quality requirements. The CMM’s digital-first architecture offers rapid measurement routines, an intuitive user experience and seamless data integration. With modular software and hardware, it is designed to scale with evolving production needs, making it ideal for aerospace, automotive, and high-precision manufacturing environments where there is a high demand for accuracy to deliver safety, compliance, and performance.

MAESTRO features a newly developed digital architecture, incorporating digital sensors, a single cable system, and a completely new

controller with brand-new firmware. Together, these new capabilities increase throughput, streamline the complete measurement operation, and ensure future-ready connectivity for modern production environments.

“Manufacturers told us they needed a next-generation system that tackles rising quality demands and skills shortages,” stated Jörg Deller, General Manager Stationary Metrology devices at Hexagon. “By rethinking our hardware and software from the ground up, rather than iterating on existing systems, we’ve had the freedom to create a high-accuracy inspection solution that is so intuitive that anyone from expert to new hires become significantly more productive. Meeting the needs of industry head-on, MAESTRO’s digital backbone also makes it straightforward to integrate into

EPoS Technologies begins production of advanced copper tungsten composites for

resistance welding applications

EPoS Technologies SA, Villaz-SaintPierre, Switzerland, has announced the launch of commercial manufacturing and sales of its eForged Copper Tungsten (CuW) composites, developed specifically for the demanding field of resistance welding.

Following the successful acquisition and commissioning of its

high-energy attrition mill at its production site in Villaz-SaintPierre, the company is now ready to deliver next-generation refractory materials to the market, said to be engineered for high performance and reliability.

EPoS’ CuW grades – CuW75 and CuW80 – are manufactured

modern connected factories, so stakeholders can improve quality quickly and definitively.”

Pilot users report dramatic productivity gains and reduced inspection lead times, helping to avoid production bottlenecks and to keep pace with fast-changing customer requirements. Customers have tested various sensors, ranging from high-speed laser scanning to tactile probes, with consistently strong results in both R&D and production applications.

Hexagon’s software tools and services, such as PC-DMIS and the Metrology Mentor, Metrology Asset Manager, and Metrology Reporting Nexus Apps, were developed in tandem with MAESTRO to create an integrated system that significantly boosts productivity from part loading to analysis, compared to isolated component solutions. The end goal is to deliver ease of use and fast workflows, from programming, execution, and usage to reporting and collaboration with colleagues in design and manufacturing.

MAESTRO will be offered initially in multiple sizes and configurations, each engineered for automated multi-sensor workflows utilising tactile probes and laser scanning probes from a new ‘digital rack’ that tracks occupancy status, sensor supply health and status that can be accessed on-device and throughout the desktop and cloud-native apps. Additional future-ready models and enhancements will follow, all based on a single, coherent platform.

www.hexagon.com

using a unique combination of advanced ball milling and its proprietary electro-sinter-forging (ESF) process. This results in ultrafine, dense microstructures that establish a new benchmark in the field.

The eForged CuW offers superior hardness for extended electrode life, enhanced resistance to deformation and wear during projection welding, and reliable performance in high-current, highpressure environments.

www.eposintering.com

Hexagon AB has launched the MAESTRO coordinate measuring machine (Courtesy Hexagon)

KIMS to commercialise rare-earth-free manganese-bismuth permanent magnets

The Korea Institute of Materials Science (KIMS) has reported a new method for producing manganesebismuth (Mn-Bi) rare-earth-free permanent magnets. Developed by Dr Ji-Hoon Park and Dr Jong-Woo Kim and their team at the KIMS Division of Nano Materials Research, the method is being commercialised by Novatech Co Ltd and will mark the first industrial application of Mn-Bi permanent magnets.

As the rare earth element market continues to fluctuate significantly, the development of permanent magnets without these elements has become increasingly urgent. While manganese-bismuth has emerged as a promising candidate, fundamental limitations have posed significant challenges to its commercialisation.

To exhibit strong magnetic properties, Mn-Bi powders must maintain a high-purity low-temperature phase (LTP); during high-temperature sintering, the powder is prone to oxidation and phase decomposition, thus making it extremely difficult to adequately densify.

To overcome these limitations, the research team developed a scalable process which includes a newly designed low-temperature sintering technique said to have increased magnet density to over 95% due to the lack of oxidation or phase decomposition. As a result, the magnets consistently achieved a maximum energy product of 10.5 MGOe (MegaGauss-Oersted). Through continued research and development efforts, the team aims to achieve a maximum energy product of 12 MGOe.

Höganäs biochar investment to reduce fossil coal use in metal production

Sweden’s Höganäs AB has released its 2024 sustainability report, highlighting progress across climate action, safety, responsible sourcing, and diversity and inclusion. In the report, the company explained its investment in biochar, a renewable carbon source. Following successful full-scale trials, it has begun planning the establishment of a biochar-receiving facility, expected to begin construction in Q2 2025. By 2026, Höganäs aims to start replacing 20% of fossil coal with biochar, in line with its climate roadmap and ambition to decarbonise production.

Two R&D projects have also been launched to accelerate the transition further: one to maximise the use of biochar in the reduction process and another to explore further fossil-free reduction technologies.

“This investment supports our customers in reducing the carbon footprint of their products and marks an important step toward nearzero direct emissions in our own production by 2030,” stated Henrik Ager, CEO of Höganäs AB. “I am also proud of the progress we have made in safety during 2024. With a 52% reduction in recordable injuries, we have clear proof of what can be

This technology can be applied across a wide range of industries, including electric vehicle motors, generators, and semiconductor components. It also enables the miniaturisation of electric motors that currently rely on ferrite magnets, while reportedly improving overall efficiency. KIMS highlighted that these Mn-Bi magnets have the potential to replace the conventional magnets used in large quantities in everyday applications and industrial systems such as air conditioning units.

“Through this research, Korea has secured the potential to become the first in the world to commercialise Mn-Bi permanent magnets,” stated lead researcher Dr Park. “If this technology is successfully commercialised, it will significantly reduce dependence on rare-earth magnets and greatly enhance the global competitiveness of domestic companies.”

This research was funded by the National Research Foundation of Korea (NRF), the Korea Institute of Energy Technology Evaluation and Planning (KETEP), and the National Research Council of Science & Technology (NST).

www.kims.re.kr

achieved through focused, companywide efforts.”

In the report, Höganäs also highlighted its continued work to advance inclusion and responsible business practices in 2024. Manager training on unconscious bias was completed, the proportion of female executive managers rose to 38%, and supplier engagement deepened through targeted sustainability dialogues as part of the Responsible Sourcing Programme.

“This report is our first step toward CSRD reporting, and more importantly, it reflects real progress,” stated Catharina Nordeman, VP Group Sustainability, Höganäs AB. “Together, we are building a more sustainable company.”

www.hoganas.com

KIMS will commercialise its Mn-Bi permanent magnet production technology through Novatech (Courtesy Korea Institute of Materials Science)

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GKN Powder Metallurgy targets sustainable and resilient regional NdFeB magnet production

As the shift to vehicles with electrified powertrains gathers pace, the need for sustainable, locally produced high-performance magnets has become critical.

GKN Powder Metallurgy is rising to this challenge by establishing NdFeB magnet production in Europe and North America, with a focus on reducing or eliminating the use of heavy rare earth elements (HREEs) such as terbium and dysprosium. In this article, Gordon Hutchinson, Vice President Magnets, outlines the company’s progress, technology strategy, and vision for a resilient magnet supply chain.

Part of the Dowlais Group plc, GKN Powder Metallurgy employs over 5,000 people across twenty-eight manufacturing locations and two innovation centres. The company is a world-leading provider of metal powders and high-precision sintered components, and is the only fully vertically integrated company in the Powder Metallurgy industry.

In co-development with its customers and business partners, GKN Powder Metallurgy offers a range of best-in-class Powder Metallurgy technologies to solve complex challenges in the automotive and industrial sectors, delivering sustainable and innovative solutions. Nearly all the material used by the company comes from recycled scrap steel, and it holds ‘Platinum’ status in the EcoVadis sustainability assessment. It supplies ten million Powder Metallurgy parts per day and makes extensive use of advanced automation and digital tools to ensure high standards of quality and delivery.

GKN PM’s mission to support regional magnet production

In 2022, GKN Powder Metallurgy began its journey to establish a sustainable and local permanent magnet production capacity. Since

then, the company has made significant progress, including establishing a technology centre in Cinnaminson, New Jersey, and developing a small-scale production line at its innovation centre in Radevormwald, Germany. The site, located an hour north of Bonn, is now preparing for

Fig. 1 Inside one of GKN Powder Metallurgy’s manufacturing sites (Courtesy GKN Powder Metallurgy)

“...GKN Powder Metallurgy identified the supply of magnets for BEVs and hybrid vehicles as a strategic opportunity. These highly engineered components are in increasing demand, yet regional supply in both Europe and North America remains limited.”

the launch of neodymium iron boron (NdFeB) magnet production, with an initial capacity of 200 tonnes per year.

This article explores GKN Powder Metallurgy’s progress in developing and industrialising magnet technology for the electric vehicle (EV) industry, with a focus on preparing for scaled production at the Radevormwald site. Of particular interest is the company’s work on magnets with reduced levels of heavy rare earth elements (HREEs) – specifically terbium (Tb) and dysprosium (Dy) – as well as HREE-free grades. These developments offer significant benefits, including cost reductions, Environmental, Social and Governance (ESG) improvements, and enhanced supply chain and geopolitical resilience, by enabling the production of high-performance magnets within local, sustainable, and robust supply chains in Europe and North America.

Navigating supply chain challenges for EV magnets

Driven by the green transition away from internal combustion engines (ICEs) toward a mix of battery electric vehicles (BEVs) and hybrids, there is increasing demand for new technologies and products to support the growing BEV and hybrid sectors. Sintered NdFeB magnets – used in over 75% of BEV or hybrid traction motors today – are a key component. These magnets are also used across a wide range of non-automotive applications, including wind energy, automation, industrial motors, and defence.

With its long-standing expertise in powder and component manufacturing, GKN Powder Metallurgy identified the supply of magnets for BEVs and hybrid vehicles as a strategic opportunity. These highly engineered components are in increasing demand, yet regional supply in both Europe and North America remains limited.

Currently, approximately 95% of magnets for EV motors are manu -

Fig. 2 Measurement and inspection of NdFeB magnets produced at GKN Powder Metallurgy’s Radevormwald site (Courtesy GKN Powder Metallurgy)

factured in China. OEM customers are, however, increasingly looking to develop a regional, localised and more sustainable supply base in Europe and North America, alongside the established supply from China. There is already a well-established supply base in Japan, but this is primarily for the domestic market.

The global supply of magnetic rare earth elements – including neodymium, praseodymium, terbium, and dysprosium – is facing increasing scrutiny due to geopolitical risks. In April, China introduced export controls on terbium and dysprosium, including their oxides and derived materials, which are exported from China and used across a wide range of industries globally. These controls require a government approval process that can take up to forty-five working days, increasing the risk of disruption, cost spikes, and long-term supply insecurity for these critical materials.

The mining and processing of the rare earth metals used in EV

“The EU passed its Critical Raw Materials Act in early 2024, aiming to enhance the development of local supplies of certain materials and reduce dependence on imports, which primarily come from China.”

magnets are associated with low ESG ratings and a history of significant environmental damage caused by extraction and refining activities. There is, therefore, a need and desire to create an improved and sustainable supply chain for these materials.

The EU passed its Critical Raw Materials Act in early 2024, aiming to enhance the development of local

supplies of certain materials and reduce dependence on imports, which primarily come from China. The Joint Research Centre assessed the supply risk of various elements identified as critical raw materials for the EU, as well as the technologies and sectors in which these materials are utilised. The light rare earth and heavy rare earth metals used in magnets are rated as the GKN Powder Metallurgy: NdFeB magnets

Fig. 3 The wire cutting of NdFeB magnets in Radevormwald (Courtesy GKN Powder Metallurgy)

“...expertise in metal powder manufacturing, combined with its capabilities in key processes used in magnet production, prompted the company to explore entry into the magnet market – a strategic move driven by growing demand from BEVs, hybrid vehicles, and wind power generation.”

highest risk in the supply chain for Europe and have a direct impact across a wide range of industries, most notably traction motors for EVs. A similar government assessment in the US has recognised the high supply chain risk associated with NdFeB magnets and their applications.

GKN Powder Metallurgy has over seventy years of experience in the supply and technology leadership

for iron powders and sintered metal components in the global automotive industry. Its expertise in metal powder manufacturing, combined with its capabilities in key processes used in magnet production, prompted the company to explore entry into the magnet market – a strategic move driven by growing demand from BEVs, hybrid vehicles, and wind power generation.

After an internal strategic review, and encouraging discussions with key customers, GKN Powder Metallurgy began its journey towards magnet production.

Towards sustainable magnets: reducing or eliminating terbium and dysprosium use

NdFeB magnets were independently discovered in 1983 by researchers at General Motors in the United States and Sumitomo Special Metals in Japan (now part of Proterial, following its earlier transition through Hitachi). Over time, magnet production in the US and Europe ceased, and had almost entirely moved to China by the late 1980s, where the mining, oxide separation, metals processing, and magnet manufacturing grew into a multi-billion-dollar industry.

Fig. 4 View of a press and jet milling equipment in Radevormwald (Courtesy GKN Powder Metallurgy)

GKN Powder Metallurgy produced magnets on a small scale in the 1980s using earlier technologies. Having re-entered the industry in 2022, GKN has undergone a rapid re-learning process to catch up with more than thirty years of global magnet technology development.

EV magnets require rare earth elements to achieve the high performance demanded in traction motors. Light rare earths, such as neodymium (Nd) and praseodymium (Pr), form the basis of strong magnetic properties, while small additions of heavy rare earths like terbium and dysprosium are used to improve thermal stability. When alloyed with iron and other elements (for example, NdFeB), these materials enable the production of magnets with high residual magnetic flux (remanence) and resistance to demagnetisation (coercivity). These properties are critical in EV motor applications, where magnets must retain performance at elevated operating temperatures of 150–200°C. However, these HREEs present significant challenges. They are the most expensive elements in magnet production, with Tb reaching $3,000 per kg in 2022, and are subject to volatile pricing and geopolitical supply risks. Further, the extraction of Tb and Dy involves intensive mining and processing, which consumes large amounts of water, acids, solvents, and energy. This has historically caused severe environmental damage, particularly in southern China and northern Myanmar. Securing a stable and sustainable supply of these critical materials is therefore a growing concern.

GKN Powder Metallurgy: NdFeB magnets

GKN Powder Metallurgy responded to these challenges by developing innovative new magnet technologies that significantly reduce – or entirely eliminate – the use of HREEs, while maintaining or enhancing performance. The company has invested in small-scale engineering facilities in the US and Germany, equipped for magnet production and testing and, over the past two years, its technical teams have developed solutions that achieve industry-leading low levels of HREE usage.

“GKN Powder Metallurgy responded to these challenges by developing innovative new magnet technologies that significantly reduce – or entirely eliminate – the use of HREEs, while maintaining or enhancing performance.”

Fig. 5 NdFeB powder jet milling machine (Courtesy GKN Powder Metallurgy)

Table 1 GKN Powder Metallurgy’s range of NdFeB magnets produced to date (Courtesy GKN Powder Metallurgy)

The company’s progress has leveraged skills in materials formulation, powder production, and magnet processing. Fast feedback trials and process optimisation were supported through benchmarking, collaborations with universities and agencies in the US, Germany, and the UK, and input from close customer partnerships. This cross-disciplinary effort has allowed GKN PM to develop and benchmark its magnets rapidly against current industry standards. The result is a range of highperformance magnets (Table 1) with reduced reliance on rare and geopolitically sensitive elements, produced using lab-scale production equipment in Cinnaminson and Radevormwald.

Magnet grades

Magnets are graded by their performance, specifically remanence and coercivity. Coercivity is especially crucial, as it correlates directly with the magnet’s ability to resist demagnetisation at high temperatures. When temperatures approach or exceed the Curie point, NdFeB magnets begin to lose their magnetic properties – making high coercivity essential for maintaining performance under thermal stress. EV motors typically operate at high temperatures, depending on the motor design and cooling circuit. To ensure reliable performance under these conditions, magnets are graded by coercivity, with industrystandard labels of ‘SH’, ‘UH’, and ‘EH’

“Notably, HREE-free magnets can be produced using rare earths sourced entirely from supply chains in Australia and the US, offering a magnet solution independent of Chinese-sourced materials. These magnets also have the best ESG rating...”

corresponding to maximum operating temperatures of 150°C, 180°C, and 200°C. GKN PM has developed optimised solutions for each of these grades of magnets, which minimise the usage of the HREE terbium and dysprosium, thereby reducing the product’s costs and ESG footprint.

SH Grade (150°C)

A HREE-free product using a special blend of light rare earth compounds to achieve the required coercivity without any heavy rare earths, providing a sustainable supply chain and enhanced ESG performance.

UH Grade (180°C)

A Tb-free product that uses dysprosium, eliminating the need for the rare and expensive Tb.

EH Grade (200°C)

A ‘Lean Tb’ product, comparable to technologies in China and Japan, that reduces the need for Tb.

Notably, HREE-free magnets can be produced using rare earths sourced entirely from supply chains in Australia and the US, offering a magnet solution independent of Chinese-sourced materials. These magnets also have the best ESG

rating, as the HREE elements are the most energy- and resource-intensive products to produce.

The magnets’ performance is measured by the energy product (BH) max, which refers to the maximum energy the magnet can transfer, and coercivity (H cj), which measures resistance to demagnetisation when exposed to external magnetic fields or temperature fluctuations. It also directly correlates with the magnet’s maximum operating temperature, making it particularly important for high-power motor applications, such as those used in EVs.

It should also be noted that the EU’s Critical Raw Materials Act aims to use 25% recycled material for NdFeB magnets by 2030. In support of this initiative, GKN PM is working with several suppliers in the EU to offer NdFeB magnets made from recycled materials to the market. Currently, GKN PM is manufacturing a sample batch of magnets made from 100% recycled materials for a major OEM as a technology demonstrator.

“Fast feedback trials and process optimisation were supported through benchmarking, collaborations with universities and agencies in the US, Germany, and the UK, and input from close customer partnerships.”

Manufacturing readiness

GKN Powder Metallurgy’s new production site for NdFeB magnets in Radevormwald, with a capacity of 200 tonnes per year, will function as a demonstrator plant for GKN to showcase its manufacturing capabilities on an industrial scale and will serve as a blueprint for future expansion in the EU and North America.

All key production machines are scheduled to arrive in the first and second quarters of 2025, with initial production samples planned for customer validation programmes in the fourth quarter of 2025. The site can be expanded as needed. GKN PM has a second-stage plan for a larger facility capable of producing up to 4,000 tonnes of NdFeB magnets annually in the EU. Additionally, manufacturing facilities are available

Fig. 6 Magnet wire cutting machines (Courtesy GKN Powder Metallurgy)

in the US to establish local capacity according to customer demand.

Conclusion

Following the chip shortages of 2021 and the changing geopolitical landscape, most automotive OEMs and EV motor manufacturers are looking to establish regional supply bases in Europe, North America, and Asia. To date, GKN Powder Metallurgy has produced magnets for twentyone different customer grades and supplied samples and test parts to

five different customers for technical evaluation. In each case, the company achieved the required magnetic properties for the applications.

The company continues to develop its product Technology Readiness Level for optimised technical solutions for NdFeB magnets. Now that the first manufacturing capability is coming online, GKN PM is working with a range of customers on programme validation requirements and commercial negotiations for the first production volumes in the near future.

Author

Gordon Hutchinson

Vice President Magnets

GKN Powder Metallurgy

Central Boulevard

Blythe Valley Park

Solihull B90 8AS UK www.gknpm.com

Fig. 7 Magnet grinding and machining line (Courtesy GKN Powder Metallurgy)

salesinfo@riotinto.com qmp-powders.com

The chemistry of LiFe: The rise of LFP batteries and what it means for the iron powder industry

Lithium iron phosphate (LFP) batteries are rapidly becoming the dominant chemistry for electric vehicles, driven by their safety, cost-effectiveness, and long cycle life. This shift presents a significant opportunity for iron powder producers, as iron is a key component in LFP cathodes. For those less familiar with the chemistry, Robert Mitchell, Principal Scientist in Energy Materials at CPI, offers a comprehensive overview of LFP’s structure, performance, and evolving production methods, and explores why LFP batteries are poised to become a major consumer of iron powders.

LiFePO 4 – lithium iron phosphate, or LFP – has long been valued for its safety and thermal stability, though historically it offered lower energy density than other cathode materials, limiting its use in mobility applications. Today, this material is set to dominate the mass-market electric vehicle (EV) sector over the next decade. In a geopolitical landscape where supply chain security is critical, metal powder manufacturers are keen to enter the market by supplying high-quality powders capable of producing LFP directly. LFP was initially reported in 1997 by members of John B. Goodenough’s research group at the University of Texas, Austin. The discovery was detailed in a paper published in the Journal of the Electrochemical Society in 1997 [1]. Goodenough, together with Michael Stanley Whittingham and Akira Yoshino, received the 2019 Nobel Prize in Chemistry for their pioneering contributions to the development of lithium-ion batteries. Goodenough’s contributions, particu -

larly to the development of LFP, played a significant role in advancing battery technology.

This material demonstrated a new approach to battery storage, featuring the reversible transport of lithium ions in and out of its structure. It increased safety and

stability, albeit with lower energy density than the incumbent LCO (lithium cobalt oxide) chemistry used in portable electronics. The discovery was patented and eventually commercialised in 2004 by the American company A123 Systems, initially for stationary storage and

1 A significant proportion of BYD vehicles use LFP batteries, including its popular Seal model (Courtesy BYD)

Fig.

“In the East, China was well into consolidating its readiness for battery production by securing access to key strategic mining resources and building out its chemical processing capabilities. CATL and BYD were enhancing their offerings [...], mastering the art of vertical integration to control the supply chain.”

power tools, with some application in electric buses. However, at the time, the energy density was too low for mass-market electric vehicles. Fig. 3 depicts the structure of (left) lithium iron phosphate (LFP) and (right) iron phosphate (FePO 4), highlighting how lithium ions are stored within the structure.

Enter the mid-2010s, and the initial patents started to run out. In the West, Tesla was a growing force in the automotive industry, representing a paradigm shift in how to operate an automotive business. As the urgency around climate change grew, Tesla thrived by developing solely electric vehicles and selling EV tax credits to conventional automakers.

In the East, China was well into consolidating its readiness for battery production by securing access to key strategic mining resources and building out its chemical processing capabilities. CATL and BYD were enhancing their offerings in cell production and electric vehicles, mastering the art of vertical integration to control the supply chain.

Fig. 3 Left: Image depicting the structure of lithium iron phosphate (LFP); right: iron phosphate (FePO 4), highlighting how lithium ions are stored within the structure [1]

Lithium Iron Phosphate LiFePO4

Iron Phosphate FePO4

CHARGE

Fig. 2 BYD’s LFP Blade Battery, described by the company as ultra-safe with a strong structure for durability, while also offering a long range and increased lifespan (Courtesy BYD)

LFP production was being set up in China after the key patents expired, with ongoing development in materials chemistry. At this time, LFP was still considered a lower energy density material; most EVs were based on another battery chemistry, NMC – a lithium cobalt oxide chemistry that swaps cobalt for nickel and manganese – to tackle consumer range anxiety. However, advancements in chemistry and its packaging were beginning to bring LFP chemistry back to the forefront in the early 2020s.

Back to basics – how does a battery work?

The key aspect of a battery is electrochemistry, in which chemical change is driven by voltage. When a battery is charged, the electrical energy is stored through the transport of metal ions and electrons within the material. For an LFP battery, the LFP cathode material is paired with a graphite anode, a plastic separator to prevent direct contact, and a liquid electrolyte which allows transport of lithium ions through the material.

Fig. 4 illustrates how an LFP battery works. Lithium ions shuttle between two electrodes inside the battery: the cathode (made of LiFePO 4) and the anode (typically graphite). At the same time, electrons flow through an external circuit, powering the connected device.

During charging, LiFePO 4 is partially reduced to FePO 4, releasing a lithium ion and an electron. The lithium ion moves through the electrolyte to the graphite anode, where it intercalates – that is, it slips between the stacked layers of graphite without significantly disturbing the structure. This allows the ion to be stored safely. The electron simultaneously travels through the external circuit, delivering power, before reuniting with the lithium ion at the anode.

When the battery discharges, the process reverses: lithium ions

Fig. 4 Electrochemical equations for the charge and discharge reaction and a visual representation of the battery operation [2]

Fig. 5 Concept of energy and power illustrated. Left: deep reserves, but narrow neck (high energy battery, but slower to charge and discharge) vs right: shallow reserves, but wide neck (less energy dense, but can charge and discharge quickly)

move back to the cathode, and electrons flow through the external circuit to supply power. Two key concepts in batteries are energy and power. To visualise this, think of two containers full of water, as shown in Fig. 5. The container on the left has a larger total volume but a narrow neck; thus, in battery

terms, it has a high energy storage capacity or energy density but a low power density, as the liquid is slow to enter or exit, analogous to slow charge or discharge. The container on the right has a lower volume but a wider opening, resulting in faster charging but a lower total energy capacity. In this

Charge: LiFePO 4 + 6 C → FePO 4 + LiC 6

Discharge: FePO 4 + LiC 6 → LiFePO 4 + 6 C

(200°C)

water, FP*, lithium carbonate, glucose (C source) Sagger filling materials (press machine)

(sander, 1.5h 250 mesh)

(electric heating, 750°C, 6-8h)

Crushing and screening (ultrafine mill, screening machine, 1-5 μm)

Dosing and mixing Package LFP

*FP is an abbreviated term for iron phosphate (FePO4) in the context of LFP synthesis

6 Example flow chart for LFP material production [3]

analogy, NMC chemistries resemble the left, while LFP represents the right. However, this perspective is shifting with advances in battery engineering, particularly with the high prevalence of LFP in China and its growth in other parts of the world.

The shift to EVs has revolved around car companies’ ability to meet consumer demand. Range anxiety has created higher expecta -

tions for energy capacity, so that an electric car can travel similar distances to an ICE vehicle. Similarly, consumers want to charge fast to replicate filling an ICE vehicle at the petrol station without disruption to their day. Battery material characteristics mean that typically a compromise has to be made somewhere in terms of cost, energy, power, cycle life, or environmental credentials.

Early EV designs have tended to focus on energy and cycle life, sacrificing power and requiring long charging protocols, such as overnight. Recently, this paradigm has been shifting, with companies such as BYD announcing in March 2025 its Super e platform, which claims to be able to charge at a rate of 10 C (meaning that the battery can be charged at ten times its nominal capacity per hour), or add 400 km in 5 minutes [4].

Fig.

How is LFP made? Key feedstocks and features

Numerous synthetic routes are employed in the production of LFP, all of which begin with an iron source. The specific form of this iron, along with its associated impurities, plays a critical role in determining the final material properties within the battery. There are several production routes for LFP, which vary in the mixing, heating, and post-processing steps.

Solid-phase

Solid-state synthesis involves mixing powders and calcining them at elevated temperatures (around 700–800°C) to form LiFePO 4

Liquid-phase

Liquid-phase mechanisms typically use pressure systems to promote reactions to form a precursor, which is then heated as mentioned above.

Fig. 6 shows an example flow chart for LFP synthesis. A critical aspect is the presence of Fe 2+, either from a precursor such as FeSO 4 or formed in the process from metallic iron. Fe 3+ oxides such as Fe 2O 3 or FePO 4 must be reduced to be suitable as a feedstock. Carbon coating is necessary for the material to function in a battery; one key method is the carbothermal reduction process, in which reduction and carbon coating occur simultaneously.

Fig. 7 A render of the preliminary design and layout of a modular One-Potenabled LFP cathode production line (Courtesy Worley and Nano One)

The synthesis of a precursor is often the first step in the process. Iron oxalate FeC 2O 4 is one such precursor that can be employed to improve control of the particle size of the product [5]. The particle size of the precursor roughly determines the product’s size, depending on the process and the time at elevated temperatures, which, if excessive, can lead to agglomeration, and thereby undesired larger clusters of particles. Milling and grinding steps are undertaken after heat treatment to adjust particle size; however, excessive milling results in fines and material loss from the process.

“Numerous synthetic routes are employed in the production of LFP, all of which begin with an iron source. The specific form of this iron, along with its associated impurities, plays a critical role in determining the final material properties within the battery.”

Generally, battery production aims to minimise the number of process steps or improve control over the final product. Using cheap or easily accessible precursors is key to this. In China, LFP production has significantly benefited from the TiO 2 industry, with the annual production capacity of TiO 2 reaching 6.05 million tonnes in 2024, representing 70% of global production. As Ilmenite FeTiO 3 is converted to TiO 2, the iron waste stream can be utilised and converted into iron phosphate (FePO 4) as feedstock for LFP. Access to this readily available precursor has allowed relatively cheap production of LFP. Canada’s Nano One announced one-pot processes to reduce processing requirements and simplify procedures [6], particularly regarding

waste reduction and avoiding the production of sodium sulphate, which is expensive to dispose of. It has been reported that Nano One was to explore the use of “Rio Tinto’s battery metal products, including iron powders from the Rio Tinto Fer et Titane facility in Sorel-Tracy, Québec” as feedstock for the production of Nano One’s cathode materials [7].

In September 2024, Hyundai Motor Company announced its partnership with Kia and EcoPro BM to produce LFP ‘directly,’ aiming to reduce processing steps and lower costs [8]. The process uses lithium, iron, and phosphate compounds (such as iron phosphate) directly for the reaction, bypassing the need for an FeSO 4 intermediate. Hyundai Steel was reported to be the supplier of iron powder [9].

Improvement

Pros Simple process, cost-effective

Cons Poor particle size control, impurities

Companies Yuneng, Wanrun, Changzhou, Liyuan etc.

• Fast-charge capability

• Higher energy density

• Requires new tooling & processes

• Commands a premium

Dual-sintering process Iron oxalate synthesis

Precise particle control, fewer impurities

Higher energy cost, lower capacity

Yuneng, Wanrun, Anda Tech

OEMs supplied by CATL HCD LFP batteries

Better uniformity and higher density

Higher costs, technical difficulties

Small particle size and high purity

Initial capital costs are higher

Shenghua Dynanonic

OEMs supplied by BYD HCD LFP batteries

Fig. 8 CRU information on 4 th generation LFP materials demonstrating high compaction density (HCD). This 4 th generation LFP represents a further step in performance for the chemistry. China has proposed export controls for high-density materials >2.58 g/cm 3. This does not ban the materials themselves, but restricts the transfer of the technology required to manufacture them overseas. Finished batteries with these materials can be exported [10]

A key challenge noted is the presence of impurities in the raw materials, which must be strictly controlled for battery production. The November 2024 announcement of the collaboration between GKN Hoeganaes and First Phosphate described in some detail the development of an LFP production route from iron powder [11].

Sweden’s Höganäs AB has listed iron powders for LFP batteries as a strategic priority in its 2024 Sustainability Report [12].

Alternative processes using elemental iron may need to form a

soluble precursor first to react effectively and create particles with the required size distribution. Fig. 8 describes some typical characteristics of battery-grade LFP from different production routes and their pros and cons.

A typical particle size for LFP powder is a D50 of the order of 1-10 microns, with an increasing trend towards smaller particles in higher-density systems. In terms of shape, LFP materials are roughly spherical particles, albeit often elongated. Maximising the packing of these particles is key to perfor -

“A key challenge noted is the presence of impurities in the raw materials, which must be strictly controlled for battery production. The

November 2024 announcement

of

the

collaboration between GKN Hoeganaes and First Phosphate described in some detail the development of an LFP production route from iron powder.”

mance, and thus, the more control over the particle size that can be achieved, the better the improvement in compaction density through the packing of the materials. The highest densities here represent so-called 4 th generation LFP, which allows thinner layers to retain still moderate energy density as well as achieve fast charging.

Following synthesis, the material is processed into a battery slurry and applied as an electrode. This typically involves dispersing the powder into a formulation using N-Methyl-2-Pyrrolidone (NMP) solvent at commercial scale, followed by coating onto a metal foil current collector. Alternative development approaches are also exploring water-based or dry processing routes. The slurry’s rheology – determined by the interaction between the powder’s surface energy and the solvent – must be carefully optimised to ensure appropriate flow and effective coating performance. Regardless of the synthesis method, controlling impurity levels remains critical to battery performance.

Impurities and their effects on the battery

Impurity levels are a crucial factor in battery performance. For example, metal contaminants can lead to plating within the battery, which can result in a short circuit of the cells and an increased risk of fire. Batterygrade precursors must contain very low levels of impurities, typically in the low ppm range – for example, less than 100 ppm in total, with some critical elements restricted to below 10 ppm.

As outlined above, various iron sources can be used in the production of LFP. However, securing suitable phosphate rock reserves for the production of high-purity phosphoric acid presents an additional challenge. In 2024, global phosphate production capacity stood at 65 million tonnes [13], with the majority derived from sedimentary rock for use in fertilisers. For battery-grade applications, however, igneous phosphate rock with low sulphur content is required to produce the necessary high-purity phosphoric acid [14]. Tables 1 and 2 give some common contaminants and their maximum levels for the production of battery materials.

LFP engineering as a route to competition

Building on the understanding of how LFP is made, the focus now shifts to the factors driving its resurgence in the competitive battery market. Battery materials are ranked by their capacity per unit mass (mAh/g), and several strategies can increase this at both the cell and pack levels. At the cell level, the current trend is an increasing density of the electrode layer. Electrodes are typically rolled in a calendaring process (Fig. 9) to reduce their thickness and densify the layer. Materials engineering is being undertaken to enhance the ability to densify these layers, with key developments focusing on improved sizing of these

Item /

Indicators

Table 1 Iron powder product specifications (Data courtesy Golden Dragon Capital Limited) [15]

Item / Indicators

Trace Elements (unit:

Table 2 Ferrous sulphate product specifications (Data courtesy Golden Dragon Capital Limited) [15]

9 Calendering process for densification of battery electrode layers (Courtesy of the author)

Fig.

Fig. 10 LFP carbon coating requirements and effect on lithium transport and battery operation (from the paper Effect of carbon coating on electrochemical performance of LiFePO 4 cathode material for Li-ion battery, H Raj, A Sil, Ionics, 2018, 2543) [16]

Fig. 11 Gravimetric energy density (Wh/Kg) as a function of maturity level from theory to pack level (From A non-academic perspective on the future of lithium-based batteries, J Frith, M. J. Lacey, U. Ulissi, Nature Comms., 2023, 420 [17]

materials to allow nanoscale precision in packing, utilising multimodal particle distributions.

Regarding electrochemical performance, a key component is the carbon coating of the particles and the engineering of this interface. LFP is electrically insulating on its own, so all manufacturing includes a step to add a carbon coating to the particles. Fig. 10 illustrates the balance in this coating, where a layer that is too thick prevents Li+ transport, while a layer that is too thin restricts electron transport and limits rate performance.

Carbon coating can be applied during production, either through in situ incorporation of a carbon precursor or as a post-processing step. Advanced methods, including those under development by Powall – a Dutch company specialising in scalable nanocoating technologies – enable continuous atomic layer deposition (ALD) of carbon onto powder surfaces to optimise this layer [18].

The true resurgence of LFP has come as a result of pack-level engineering. Overall, the increases in density and carbon loading for electron transport at the cell level lead to a high energy density. However, when it comes to a battery pack, safety is paramount. The traditional route considers building cells into a module and then modules into packs.

Recent developments in Chinese battery production have skipped the module level, with cell-to-pack or even cell-to-body constructions, whereby the cell forms a structural component of the pack or vehicle structure. This is more readily achievable with LFP, which is inherently safer due to its higher thermal runaway onset temperature. As a result, the quantity of non-active components can be reduced. This means that at the pack level, despite LFP having a lower capacity per gram at the material level, it can still be competitive in terms of pack-level energy density. This is the driving force behind LFP’s application in the automotive sector (Fig. 11).

Precursor cost requirements and the battery market

China has become a dominant force in LFP battery production, in part due to its large titanium dioxide (TiO 2) industry’s by-products which offer cost-effective feedstock for producing LFP cathode materials. Fig. 12 shows data from CRU on the general cost split of Chinese batteries. As seen, raw materials represent the bulk of the battery cost, and the trends in battery price closely follow that of lithium carbonate. This cost is typically around 60% of the overall battery cost. Hence, cheap precursors are required to make cheap batteries. Prices are typically quoted in $/kWh, meaning cost per kWh of capacity.

In general, the prices of battery systems have dropped considerably in the past fifteen years, driven by economies of scale, improved material efficiency, and streamlined manufacturing processes. Currently, over 70% of the world’s batteries are produced in China, and these are cheaper than their European and North American counterparts by 30% and 20%, respectively [19].

The drive for cheaper batteries pressures material manufacturers to supply materials at a lower cost. In May 2025, Chinese prices for high-grade LFP battery material are around $3,900 per tonne, and battery-grade iron powder is approximately $800 per tonne (excl. tax) [20, 21], In comparison, the largest cost comes from lithium carbonate, which is around $8,000 per tonne at current pricing. Battery prices, in general, have been declining since 2022 when lithium precursor costs rose to $75,000 per tonne [22].

Conclusion

China is set to remain the dominant force in LFP battery production. However, other regions are steadily expanding their capacity. Establishing a competitive ex-China supply chain will depend on securing

Fig. 12 Cost trends for LFP batteries and split by process, showing raw materials as the highest component (Data: CRU Battery Cost Model; LCE = Lithium Carbonate Equivalent) [23]

“The battery industry continues to offer significant opportunities for the development of localised supply chains, which are vital to achieving climate targets, lowering costs, and ensuring long-term supply security.”

high-purity, low-cost precursors –essential for enabling supply chain resilience and supporting net-zero ambitions. Drivers include economic competitiveness, national security, environmental policy, and trade regulations. For instance, under the UK’s rules of origin, a proportion of a battery’s components must be sourced from the UK or EU to avoid a 10% cross-border tariff.

Mineral security is also rising on the agenda. Governments are responding with initiatives such as the UK–India Technology Security Initiative [23] and the US–Ukraine minerals agreement [25], which aim to ensure access to critical raw materials and promote domestic processing. Reflecting this strategic

shift, the UK added iron to its critical minerals list in 2024 [26] – alongside lithium and phosphorus – due to its importance to both the steel and battery sectors.

The battery industry continues to offer significant opportunities for the development of localised supply chains, which are vital to achieving climate targets, lowering costs, and ensuring long-term supply security. LFP has progressed from a niche chemistry to a mainstream solution for EV and energy storage applications, driven by innovations in materials and pack design.

Metal powders can play an important role in this transition –particularly if they are tailored for integration into battery processes.

“Metal powders can play an important role in this transition – particularly if they are tailored for integration into battery processes. One-pot synthesis routes, for example, offer potential to simplify production, lower costs, and reduce environmental impact.”

One-pot synthesis routes, for example, offer potential to simplify production, lower costs, and reduce environmental impact. Success will hinge on controlling impurity levels and achieving competitive costs, with Chinese suppliers already operating near raw material-level pricing.

Looking ahead, battery chemistries will continue to evolve. LMFP, which introduces manganese into the LFP structure, can deliver

higher voltage and energy density. Sodium-ion batteries – many of which also rely on iron-based chemistries – are also gaining traction, potentially expanding the role of iron powders in next-generation systems. China’s lead has shown that ready access to feedstock is critical to industrial scale-up. For Western economies, developing reliable sources of metal powder that can

be processed into battery-grade materials will be essential for securing supply chains. New market entrants will need to match performance, sustainability, and cost benchmarks in order to compete in the global LFP ecosystem.

Author

Robert Mitchell

Principal Scientist, Energy Materials CPI

The Wilton Centre Wilton, Lazenby, Redcar TS10 4RF UK www.uk-cpi.com

References

[1] A.K. Padhi, K.S. Nanjundaswamy, J.B. Goodenough, ‘Phospho-olivines as positive-electrode materials for rechargeable lithium batteries,’ Journal of The Electrochemical Society, 1997, 144 (4), 1188–1194

Fig. 13 It has been reported that from 2026 Volkswagen will extensively use LFP batteries, including in its ID 3, ID 4 and ID 7 (Courtesy VW)

[2] U.S. Department of Energy, ‘How Lithium-ion Batteries Work’, Energy Saver, 28 Feb 2023, https://www. energy.gov/energysaver/articles/ how-lithium-ion-batteries-work

[3] Cathode Solution, ‘What is the LFP cathode synthesis process’, https:// www.cathodesolution.com/post/ what-is-the-lfp-cathode-synthesisprocess

[4] BYD, ‘BYD unveils Super e-Platform with megawatt flash charging’, https://www.byd.com/mea/ news-list/byd-unveils-super-e-platform-with-megawatt-flash-charging

[5] BYD, ‘Method for preparing lithium iron phosphate ferrous oxalate’, Patent CN101200422B, https://patents.google.com/patent/ CN101200422B/en

[6] Nano One, ‘Nano One provides progress update on its alliance with Worley and cost comparison demonstrating the case for One-Pot™ enabled LFP cathode production’, https://nanoone.ca/news/nano-oneprovides-progress-update-on-its-alliance-with-worley-and-cost-comparison-demonstrating-the-case-for-onepot-enabled-lfp-cathode-production/

[7] Rio Tinto, ‘Nano One and Rio Tinto announce strategic partnership and US$10M investment’, https:// www.riotinto.com/en/can/news/ releases/2022/nano-one-and-riotinto-announce-strategic-partnershipand-us10m-investment

[8] Hyundai Motor Company, ‘Hyundai Motor and Kia team up with Hyundai Steel and EcoPro BM to enhance EV battery technology’, https:// www.hyundai.com/worldwide/en/ newsroom/detail/hyundai-motorand-kia-team-up-with-hyundaisteel-and-ecopro-bm-to-enhance-evbattery-technology-0000000835

[9] GKN Hoeganaes to support First Phosphate in LFP cathode active material development. Metal Powder Technology. November 20, 2024. Available at: https://www.metal-powder.tech/ gkn-hoeganaes-to-support-first-phosphate-in-lfp-cathode-active-materialdevelopment/

[10] Sam Adham, ‘High Compacted Density (HCD) LFP Cathode Material: A Game Changer for EV Batteries’, LinkedIn, https://www.linkedin. com/posts/sam-adham_lfp-batterymaterials-batterymanufacturingactivity-7275859602355761152-ov-w

[11] GKN Hoeganaes, ‘GKN Hoeganaes to support First Phosphate in LFP cathode active material development’, https:// www.metal-powder.tech/ gkn-hoeganaes-to-support-firstphosphate-in-lfp-cathode-activematerial-development/

[12] Höganäs, ‘Sustainability report 2024’, https://www.hoganas.com/ en/sustainability/sustainabilityreport

[13] U.S. Geological Survey, ‘Phosphate Rock’, Mineral Commodity Summaries, January 2025, https:// pubs.usgs.gov/periodicals/ mcs2025/mcs2025-phosphate.pdf

[14] Andrea Hotter, ‘Don’t forget phosphate when securing critical raw materials for electrification’, Fastmarkets, 10 March 2023, https://www.fastmarkets.com/ insights/dont-forget-phosphate-forelectrification-andrea-hotter/

[15] Brendan Jephcott, ‘LFP cathode material raw materials (nonexhaustive)’, LinkedIn, https:// www.linkedin.com/posts/brendanjephcott_lfp-cathode-material-rawmaterials-non-exhaustive-activity7318447538779443201-FAvW/

[16] Raj, H., & Sil, A. (2018). Effect of carbon coating on electrochemical performance of LiFePO4 cathode material for Li-ion battery. Ionics, 24(9), 2543–2553. https://doi. org/10.1007/s11581-017-2423-0

[17] Frith, J. T., Lacey, M. J., & Ulissi, U. (2023). A non-academic perspective on the future of lithium-based batteries. Nature Communications, 14(1), 420. https://doi.org/10.1038/ s41467-023-35933-2

[18] Powall, ‘Atomic Layer Deposition (ALD)’, https://powall.com/ technology/#:~:text=Atomic%20 Layer%20Deposition%20

(ALD)&text=ALD%20deposits%20 ultrathin%20films%20with,cost%20 effectively%20and%20at%20scal

[19] International Energy Agency (IEA), ‘The battery industry has entered a new phase’, 5 March 2025, https://www.iea.org/ commentaries/the-battery-industryhas-entered-a-new-phase

[20] Bekker, M. (2025). Battery Materials Market Prices: Week Ending 1 May 2025. LinkedIn. https://www.linkedin.com/pulse/ battery-materials-market-pricesweek-ending-1-may-2025-magnusbekker-mimgc/?trackingId=nS0E1ZI SvIVYqV7Lv8k9mQ%3D%3D

[21] Shanghai Metal Market (SMM), ‘Lithium Battery Cathode Material Prices’, 16 May 2025, https://www. metal.com/en/markets/41

[22] Lucas, A. (2023). ‘Lithium market update: Elevated prices are creating favourable dynamics for miners’, ETF Stream. https:// www.etfstream.com/articles/ lithium-market-update-elevatedprices-are-creating-favourabledynamics-for-miners

[23] Adham, S. (2023). ‘Battery manufacturing: Only the lowest-cost producers will survive’, LinkedIn. https://www.linkedin.com/ posts/sam-adham_sustainabiltybatteries-manufacturing-activity7272254367158702081-cImc

[24] UK Government, ‘UK-India Technology Security Initiative factsheet’, 25 July 2024, https:// www.gov.uk/government/ publications/uk-india-technologysecurity-initiative-factsheet/ uk-india-technology-security-initiative-factsheet

[25] Aikman, I., & da Silva, J. (2025). ‘What we know about US-Ukraine minerals deal’, BBC News. https:// www.bbc.co.uk/news/articles/ cn527pz54neo

[26] British Geological Survey (BGS), ‘UK 2024 Criticality Assessment published’, 28 November 2024, https://www.bgs.ac.uk/news/ uk-2024-criticality-assessment/

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Learn more about Quintus’ large-scale PM-HIP solution in our whitepaper or visit the Knowledge Center on our website.

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Driving sustainable innovation: HIP 2025 explores the strategic potential of Hot Isostatic Pressing

The 14 th International Conference on Hot Isostatic Pressing (HIP 2025), held in Aachen, Germany, brought together over 250 global experts to examine the expanding role of HIP in critical industries. With a strong focus on nuclear power, large-scale component production, and process innovation, the event highlighted HIP’s potential to deliver defect-free, high-integrity parts. As RWTH Aachen’s Yuanbin Deng, Felix Radtke, Ziping Sang, Jonas Koob, Frederik Tegeder, and Anke Kaletsch report, HIP 2025 highlighted the technology’s strategic value in enabling safe, reliable, and sustainable manufacturing for demanding applications.

HIP 2025, the 14 th International Conference on Hot Isostatic Pressing, took place in Aachen, Germany, from 6 to 10 April 2025.

The event, which attracted over 250 attendees from over twenty countries, served as a platform for researchers, industry experts, and equipment manufacturers to share advanced insights and foster innovations in HIP technology across various applications.

Held at the Tivoli Football Stadium, the three-day conference programme included four keynote lectures by leading international experts, two panel discussions on current and future challenges in HIP, and over eighty scientific and technical presentations across fourteen specialised sessions. A dual-track schedule allowed attendees to tailor their experience to specific interests, while over twenty exhibitors showcased advanced HIP technologies, services, and applications.

Beyond the technical programme, the conference featured curated networking events and exclu -

sive facility tours, fostering deeper collaboration between academia and industry. All exhibitors, large and small, showcased cutting-edge developments, creating a collaborative and close-knit environment for exchange.

Exploring HIP materials, processing and markets

HIP 2025’s technical programme explored critical aspects of material behaviour, equipment innovation, and industrial application across

Fig. 1 A plenary session at HIP 2025 (Courtesy Jenö Gellinek/TEMA Technologie Marketing AG)

key sectors, including aerospace, energy, oil and gas, nuclear, advanced ceramics, and tooling. A focal point of the conference was the integration of HIP with Additive Manufacturing technologies, highlighting the synergistic potential to create geometrically intricate components and develop innovative in-situ alloyed materials.

Modelling and simulation were emphasised as indispensable tools for predicting microstructural evolution, near-net-shape component dimensions, and final component properties, enabling data-driven optimisation of HIP process parameters. Sustainability also featured prominently, with numerous presentations addressing energy-efficient process design and the adoption of environmentally responsible feedstock materials, underscoring the industry’s growing commitment.

Exhibition and poster highlights

In addition to the technical sessions, a comprehensive industry exhibition featured innovations from over twenty international companies and research institutions, highlighting the latest developments in HIP systems, equipment, and manufacturing technologies.

The HIP 2025 exhibition provided an invaluable opportunity for networking, knowledge sharing, and collaboration between academia and industry. A dedicated poster session created an engaging and informal setting for early career researchers to present their work and engage in meaningful discussions with experienced professionals, promoting intergenerational dialogue and mentorship.

Technical tours

Organisers dedicated the final day of the event to technical tours, giving attendees the opportunity to explore regional industrial and research sites that actively use HIP systems. Participants were able to choose from three specialised tours. One group visited Cremer Thermoprozessanlagen GmbH in Düren, a leading furnace manufacturer

Fig. 2 A comprehensive industry exhibition showcased cutting-edge innovations from over twenty international companies and research institutions (Courtesy Jenö Gellinek/TEMA Technologie Marketing AG)

that specialises in the design and production of HIP systems. Another tour took participants to OWL GmbH in Aachen, a HIP service provider that delivers contract HIP solutions to a range of industries. The third group visited the Institute for Materials Applications in Mechanical Engineering (IWM) at RWTH Aachen University, which specialises in HIPrelated research areas including process simulation, alloy development, and the combination of HIP with Additive Manufacturing.

Technology development, applications and academic frontiers of HIP

The keynote presentations at HIP 2025 highlighted the critical role of advanced manufacturing technologies, particularly HIP, in meeting the world’s growing energy needs while significantly reducing global CO 2 emissions. As nations accelerate their transitions to sustainable energy systems, the need for reliable, high-performance components produced by robust processes such as HIP has never been more urgent.

HIP’s role in clean energy and nuclear power

In the context of the United States’ goal to achieve net-zero carbon emissions by 2050, David Gandy, Principal Technical Executive for Nuclear Materials at the Electric Power Research Institute (EPRI), underscored the indispensable role of nuclear power in the nation’s clean energy strategy. He emphasised that meeting the growing demand for clean, baseload electricity will require not only the expansion of nuclear capacity but also the modernisation of the existing reactor fleet. Central to this effort is deploying advanced nuclear reactors designed to operate at elevated temperatures and stresses, conditions that necessitate the use of highly integrated materials. Mr Gandy emphasised that HIP is a key enabler in this context, offering the ability to produce defect-free,

“Mr Gandy emphasised that HIP is a key enabler in this context, offering the ability to produce defect-free, high-performance metal and ceramic components that are essential for the safe and efficient operation of next-generation reactor systems in a timely fashion.”

high-performance metal and ceramic components that are essential for the safe and efficient operation of next-generation reactor systems in a timely fashion.

To meet these demands, Mr Gandy stated that the global HIP market must double over the next fifteen years. Achieving this will require a substantial increase in powder production, the expansion of HIP capacity worldwide, and the development of equipment capable of processing larger and more complex

components. He also stressed the importance of robust cross-sector collaboration – involving powder producers, HIP equipment manufacturers, PM-HIP part producers, and end-users – to support the entire HIP lifecycle, from design through to maintenance and recycling. This coordination will enhance supply chain resilience and foster innovation in developing components that satisfy the rigorous demands of advanced energy systems.

Fig. 3 David Gandy, Principal Technical Executive for Nuclear Materials at the Electric Power Research Institute (EPRI), underscored HIP as a key enabler of the deployment of advanced nuclear reactors (Courtesy Jenö Gellinek/TEMA Technologie Marketing AG)

“A key focus for Framatome is the development of standardised qualification procedures to support the broader adoption of HIP in both conventional and advanced nuclear power plants.”

Advancements in HIP technology and manufacturing

Dr Louis Lemarquis of Framatome further explored the role of HIP in the nuclear industry, focusing on its ability to improve component integrity, enable new design freedoms, and offer alternative manufacturing routes. He highlighted the inclusion of HIP in Framatome’s global advanced manufacturing development.

Drawing on Framatome’s experience, Dr Lemarquis emphasised the growing importance of HIP for powder consolidation and the steady development of this technology over twenty years. He detailed key technical aspects, including porosity control, geometry constraints, and sizedependent process optimisation. He presented case studies showing successful applications of HIP

in near-net-shape parts for the nuclear industry, such as an eight tonne primary elbow demonstrator. Finally, he identified key challenges in integrating HIP into core manufacturing, such as material qualification and regulatory compliance. A key focus for Framatome is the development of standardised qualification procedures to support the broader adoption of HIP in both conventional and advanced nuclear power plants. From a complementary perspective, Dr Anders Eklund of CISRI-HIPEX Technology Co, Ltd traced the development of HIP technology and equipment in China. His keynote outlined a five-decade journey that began with reliance on Russian technology and evolved through sustained domestic innovation. Over time, China has welcomed a growing number of HIP manufacturers, including foreign players, as the market has matured and increasingly integrated new technologies.

Fig. 4 HIP 2025’s conference chairs, Jim Shipley (left) Manager – Business Development, Quintus Technologies AB, and Prof Dr -Ing Christoph Broeckmann (right), Head of Institute IWM and IAPK (Courtesy Jenö Gellinek/TEMA Technologie Marketing AG)

In recent years, there has been a surge of interest in HIP, particularly in the aerospace and energy sectors. Dr Eklund discussed emerging trends such as the development of larger, standardised, and modular HIP units and advances in process simulation using digital tools. He presented recent innovations, including improvements in pressure, temperature control, and cooling rates, and offered insights into the next steps expected in the country’s HIP development.

Expanding the market for HIP

Expanding the market for HIP requires not only technological advances but also strategic efforts to broaden the range of applications. To address this challenge, Prof Hamish Fraser, Center for the Accelerated Maturation of Materials, Department of Materials Science and Engineering, The Ohio State University, emphasised the importance of applying fundamental material science principles to opening up new avenues for HIP. He presented three illustrative case studies:

Optimisation of titanium alloys for turbine rotors

Prior particle boundaries

In Ni-base superalloys, oxideinduced prior particle boundaries (PPBs) hinder recrystallisation. Using advanced SEM imaging and crystallographic mapping, Prof Fraser demonstrated that powders produced by the Plasma Rotating Electrode Process (PREP) have cleaner surfaces and fewer PPBs than gas-atomised powders.

Cost reduction through powder blending

Prof Fraser proposed a costeffective approach by blending elemental powders (e.g. Ti6Al4V + Fe) for HIP of refractory alloys. CALPHAD-based simulations were used to identify optimum heat treatment temperatures to ensure chemical homogeneity.

The addition of Fe to Ti6Al4V creates a metastable β -phase, which upon heat treatment forms a refined α -phase distribution, potentially increasing fatigue strength, suggesting that HIP is a viable route for critical aerospace components.

Prof Fraser concluded that the combination of advanced characterisation, computational thermodynamics, and tailored heat treatments opens up new avenues for HIP to meet stringent mechanical and economic performance requirements. Taken together, these expert contributions confirm the strategic value of HIP in developing

“As the world approaches 2050 climate targets, continued investment in HIP technologies and collaborative innovation will be essential to supporting the growing demand for high-performance components in energy, aerospace, and beyond.”

Fig. 5 Prof Hamish Fraser, Center for the Accelerated Maturation of Materials, Department of Materials Science and Engineering, The Ohio State University, speaking at HIP 2025 (Courtesy Jenö Gellinek/TEMA Technologie Marketing AG)

resilient, low-carbon energy infrastructures. As the world approaches 2050 climate targets, continued investment in HIP technologies and collaborative innovation will be essential to supporting the growing demand for high-performance components in energy, aerospace, and beyond.

Component and equipment manufacturing challenges

PPB defects panel discussion

An intensive panel discussion at HIP 2025 focused on the PPB defects during HIP, particularly in materials such as nickel-base alloys. PPB defects result from the precipitation of undesirable second phases – such as carbides, oxides, or other impurities – along powder particle boundaries, forming thin interfacial layers. These inhibit consolidation during HIP by acting as non-bonded or weakly bonded interfaces, and degrade mechanical performance

by reducing ductility, creep resistance, and fatigue strength, while promoting early fracture. Solutions to minimise PPB defects have attracted much attention. Among these, powder quality control is widely recognised as one of the most effective approaches. The use of high-purity powders with oxygen content reduced to below 50 ppm can significantly suppress oxide formation at leading particle boundaries. In addition, reducing the levels of carbon and other impurities helps to prevent the precipitation of carbides and intermetallic compounds. Modification of particle morphology has also been proposed to promote surface diffusion over volume diffusion, thereby reducing PPB formation.

Regarding control of particle size distribution, one panellist emphasised that powder production is typically designed within defined minimum and maximum size limits. Even if fine particles are removed, small satellite particles attached to

larger powder particles can still degrade performance. Conversely, a narrower particle size distribution increases direct contact between larger particles and minimises the presence of multilayers of small particles around large particles, thereby reducing satellite formation.

In terms of oxidation behaviour, although smaller particles are more susceptible to oxidation due to their higher surface reactivity, they also have a greater specific surface area in the consolidated microstructure. Therefore, a balanced mixture of small and large particles is required to optimise densification and control the extent of PPB formation.

Microwave powder cleaning has also been proposed as a novel technique to improve powder purity and reduce the risk of PPB defects. However, it remains largely experimental and is generally not suitable for HIP components with large dimensions. In contrast, degassing is a well-established step in HIP preparation, commonly used to

Fig. 6 A panel discussion on the topic of ‘Upcoming Giga-HIPs’ (Courtesy IWM)

remove adsorbed gases and volatile contaminants from powder surfaces.

Nevertheless, questions were raised about atmosphere control throughout the HIP canister preparation and filling process. In response, one panellist shared his experience with the careful processing of Alloy 720 powder, where the entire HIP preparation was carried out under vacuum, resulting in excellent consolidation quality. However, he also emphasised that this level of powder processing and handling was exceptional and challenging to replicate on a large scale.

Another panellist agreed that careful processing can prevent PPB defects, but noted that for large HIP components involving several tonnes of powder, maintaining vacuum conditions throughout the canister preparation process presents significant practical challenges. For post-processing of HIPed components, thermomechanical processing is a good option as it fragments second-phase networks, promotes recrystallisation, and increases grain boundary strength.

Giga-HIP panel discussion

Another panel discussion focused on the challenges associated with Giga-HIP, a process that enables the consolidation of extremely large or high-volume components that were previously beyond the capabilities of conventional HIP systems. Among these challenges, cost was a primary concern. Key cost drivers include high energy consumption due to prolonged high temperature and high pressure cycles, the cost of large-scale equipment, and the need for tight control of powder quality and process atmosphere. For such large components, inadequate preparation can lead to significant additional costs. In addition, pre-HIP operations such as forging or welding can add further cost and complexity. Therefore, accurate cost estimation prior to machining is essential.

One approach discussed was the possibility of producing halfsize components and welding them together, which was considered a viable option. Alternatively, producing a large number of smaller components instead of one large component was suggested, although it was noted that powder filling for each unit is time-consuming. Despite these challenges, the development of advanced technologies such as Giga-HIP inevitably involves some risk, but continued exploration is considered worthwhile.

Awards

Lifetime Award

Dr Susan Davies of Bodycote IMT received the prestigious award of the International HIP Committee for her outstanding lifetime contribution to the implementation and strategic development of HIP technology.

Dr Susan Davies of Bodycote IMT was selected by unanimous decision of the International HIP Committee (IHC) in recognition of her outstanding career-long contributions to the industrial implementation and strategic advancement of HIP technology. Throughout her thirty-four-year career in HIP technology, Dr Davies has played a key role in advancing HIP from a specialised densification process to a widely adopted manufacturing technology in the aerospace, energy, medical, and tooling sectors. At Bodycote IMT, she has led the integration of HIP into production lines, improving performance and minimising postprocessing requirements. Her work has enabled the application of HIP to critical components. In addition to her technical contributions, Dr Davies has influenced global HIP strategy, participated in the development of standards,

Fig. 7 Dr Susan Davies, Bodycote IMT, received a lifetime achievement award from the International HIP Committee (Courtesy Jenö Gellinek/TEMA Technologie Marketing AG)

and mentored the next generation of engineers. This award recognises her leadership and commitment to bridging the gap between research and industrial practice, strengthening HIP’s role in high-performance, sustainable manufacturing.

Best Component

Award

Proxima Powder Metallurgy received a Best Component Award in recognition of its exceptional efforts in developing a largescale, complex-shaped component made from a titanium alloy using a novel technology of HIP capsule manufacturing. This achievement demonstrates the level of precision and innovation that can be achieved with modern Powder Metallurgy techniques, particularly when processing challenging materials, such as titanium.

Best Poster Award

A special highlight was the presentation of two Best Poster awards, which went to Reine Mvodo Eba (Laboratoire ICB) and Leonhard Gertlowski (IWM, RWTH Aachen University).

Leonhard’s poster was titled, ‘Accelerated fatigue testing of PM-HIP high-speed steel for nearnet-shape applications,’ and Reine’s contribution was entitled ‘Design of new composite duplex stainless steels by powder mixture and load-assisted sintering.’ The awards recognise the exceptional quality of their work, which contributed significantly to the technical programme of the HIP 2025 conference. Winners were selected by the International HIP Committee and honoured during the conference dinner.

Future prospects for HIP

The discussions at this conference made one thing clear: HIP will play a critical role in meeting the challenges of the energy transition and the growing demand for high-performance, durable components. In particular, HIP is emerging

Fig. 10 Reine Mvodo Eba, Laboratoire ICB, receiving a Best Poster Award (Courtesy IWM)

Fig. 8 A Best Component Award was presented to Proxima’s Alessandro Sergi and Thomas Oulton (Courtesy IWM)

Fig. 9 Leonhard Gertlowski, IWM, RWTH Aachen, receiving a Best Poster Award (Courtesy IWM)

as a key technology that enables the production of dense, robust materials required for advanced energy and reactor systems. Looking ahead, critical areas of focus will include integrating HIP with Additive Manufacturing, digitising process control through simulation and digital twins, developing sustainable materials, and designing larger, more energy-efficient HIP systems. International collaboration will also be essential to expand global manufacturing capabilities and harmonise standards. These advances will enable HIP to make a decisive contribution to the realisation of climate-neutral and sustainable technologies.

With HIP 2025 now concluded, the community looks to the future. The fifteenth International HIP Conference will be held in Busan, South Korea, in 2028, continuing the tradition of global exchange and innovation. We look forward to welcoming you there to help shape the future of HIP technology.

Acknowledgements

The IHC, the HIP 2025 Technical Committee, and the Institute for Materials Applications in Mechanical Engineering (IWM) at RWTH Aachen University would like to thank all participants for their valuable contributions and enthusiastic engagement. Our sincere thanks also go to TEMA Technologie Marketing AG for their outstanding organisational support, which played a crucial role in the success of this event. In particular, we would like to thank all the sponsors whose generous support made this event possible:

Platinum Sponsor Quintus Technologies

Gold Sponsors

American Isostatic Presses (AIP) Inc; Bodycote; Cisri Hipex Technology Co Ltd; Engineered Pressure Systems International NV (EPSI); Hiperbaric High Pressure Technologies; MTC Powder Solutions; Wallwork Group Ltd.

Silver Sponsors Cremer Thermoprozessanlagen GmbH; Isostatic Forging International (IFI) Europe; Isostatic Pressure Solutions BV; Kittyhawk Inc; Pressure Technology Inc.

Thank you for the invaluable contributions to advancing Hot Isostatic Pressing technologies and fostering collaboration between industry and academia.

Authors

Yuanbin Deng, Felix Radtke, Ziping Sang, Jonas Koob, Frederik Tegeder & Anke Kaletsch

Institute for Materials Applications in Mechanical Engineering (IWM)

RWTH Aachen University Aachen, Germany

www.iwm.rwth-aachen.de y.deng@iwm.rwth-aachen.de

Fig. 11 Group picture of the participants in front of the Aachen Tivoli (Courtesy Jenö Gellinek/TEMA Technologie Marketing AG)

High-precision press solutions for permanent magnets in EVs and green energy generation

As the demand for electric vehicles and renewable energy technologies continues to grow, so too does the need for high-performance permanent magnets. These critical components, particularly NdFeB magnets, require advanced production methods to achieve the required magnetic properties and geometric precision. This article explores the role of pressing technologies in magnet manufacturing, with a focus on DORST Technologies’ solutions designed to ensure consistent quality, material efficiency, and process control in modern magnet production.

Our understanding of magnetic properties has evolved significantly since the discovery of magnetite, with early advancements in Europe tracing back to ancient Greece. The first permanent magnets produced with Powder Metallurgy (PM) emerged in the form of aluminiumnickel-cobalt (AlNiCo) magnets in the 1920s and 1930s. In the 1950s, their range expanded with hard ferrites, and was further broadened in the 1960s and 1970s with the discovery of rare earth magnets made from samarium-cobalt (SmCo) and, later, neodymium-iron-boron (NdFeB) alloys.

To this day, NdFeB magnets are recognised as the strongest type of permanent magnet, driven by their high energy product. A magnet’s energy product (written as BH max) is a measure of the strength of a permanent magnet, calculated by the point on the magnet’s demagnetisation curve where the product of B (magnetic flux density) and H (magnetic field strength) is largest, relative to its size.

Any increase in magnetic properties can only be achieved through advances in production technology, making the pressing process a crucial step in magnet production.

DORST Technologies supplies equipment for various stages of magnet manufacturing: equipment for spray drying material, pressing technology

with forces from 15-1,600 tonnes –some designed for inert atmospheres to accommodate materials sensitive to atmospheric oxygen – and custom magnetising coils and rectifiers to facilitate compaction in a magnetic field. Automation solutions are available to ensure effective cleaning and handling of the pressed magnets.

Fig. 1 According to the European Raw Materials Alliance (ERMA), demand for rare earth magnets is set to dramatically increase in the coming decade (Courtesy DORST Technologies)

“...discoveries of rare earths outside China, coupled with support programmes in the US and the European Union, such as the European Critical Raw Materials Act, are expected to lessen the dependencies on China formed over the past twenty years.”

Renewable and green technologies drive market development

Growing awareness of global warming has resulted in the demand for technologies and solutions that reduce CO 2 emissions. Magnet technologies are required in the expanding renewable energy market, particularly for wind power and energy storage, as well as for the electric motors used in electric vehicles (EVs).

According to the European Raw Materials Alliance (ERMA), demand for rare earth magnets in modern gearless wind turbines is expected to reach 15,000 tonnes by 2027, while annual demand for electric vehicle (EV) motors could rise to 70,000 tonnes by 2030. Meeting this growing demand is challenging, given China’s dominance in rare earth production, however there are efforts in Europe and the US to develop independent supply chains.

China has previously imposed export restrictions on rare earths and is likely to continue this practice in the future. However, discoveries of rare earths outside China, coupled with support programmes in the US and the European Union, such as the European Critical Raw Materials Act, are expected to lessen the dependencies on China formed over the past twenty years.

Individual press solutions from 15 to 1,600 tonnes

DORST Technologies began building axial magnet presses in the 1980s, initially using mechanical presses as the basis for its designs. The company has since developed wet presses featuring a magnetic alignment system for producing hard ferrite magnets. Its current presses which exert forces between 15-200 tonnes are exclusively powered by servo-electric drives. For pressing forces ranging from 300-1,600 tonnes, however, servo-hydraulic drives have proven to be the most

Fig. 3 Key markets for magnet technology: energy, mobility, medical, and aviation (Courtesy DORST Technologies)

Fig. 2 Evolution of BH max (Energy Product) in permanent magnets from 1900 onwards, measured in kJ/m³ (Courtesy DORST Technologies)

effective solution. Over the past two years, the company has received numerous orders for axial magnet presses with these pressing forces, all of which have been built, delivered, and commissioned.

One of the key benefits that sets servo-electric and servo-hydraulic presses apart from mechanical presses is their ability to offer completely independent CNCcontrolled closed-loop operation for each axis. Each axis operates independently, providing the flexibility and precision required for highly accurate pressing cycles. If necessary for axial compaction, this enables additional closed-loopcontrolled relative movements of the coil package and, thus, the magnetic field in relation to the die.

The suitable positioning of the magnetic field and the magnetic field strength can also help with the filling of the powder into the cavity, allowing the powder to be ‘sucked’ into the cavity magnetically. This proven pressing technology thus provides ideal conditions for a powder-saving production of magnets, either as semi-finished products or very precisely near netshape.

Pressing in a magnetic field

The electrons and atomic nuclei of a solid body have magnetic dipole moments. Ferromagnetism is manifested when the magnetic moments of the electrons of neighbouring atoms interact and align in parallel or antiparallel once an external magnetic field is applied. Soft magnets are characterised by the fact that this polarisation only exists as long as the external field remains. In contrast, hard magnets and permanent magnets see polarisation remain even after the external field has been removed. All materials affect a magnetic field to some extent when introduced into it. The magnetic moments of the electrons in the material interact with the external field, causing the material

“One of the key benefits that sets servoelectric and servo-hydraulic presses apart from mechanical presses is their ability to offer completely independent CNC-controlled closed-loop operation for each axis.”

to become polarised. This polarisation can only be cancelled by a field of opposite orientation, an alternating field of decreasing strength, or heating it to a temperature higher than the Curie temperature of the respective material.

Permanent magnets with crystalline anisotropy (ferrite, SmCo, NdFeB) are pressed within a magnetic field, then sintered, processed, and finally magnetised. When pressing in a magnetic field, a distinction is made between transverse field pressing and axial field pressing. Selecting the appropriate magnet press requires determining

the shape and maximum size of the magnets to be pressed.

Pressing in a transverse field is realised with two vertical magnetising coils (Fig. 4). The process should be evaluated in terms of required tool optimisation and ease of part removal. When pressing in an axial field, coils are positioned horizontally. Solutions exist with either a single coil or a pair of coils, depending on the desired uniformity of the magnetic field for pressing. Throughout the compaction process, the magnetic field may be turned on or off, with strength adjusted according to specific requirements.

Fig. 4 Pressing in a transverse field realised with two vertical magnetising coils (Courtesy DORST Technologies)

“To achieve the best particle alignment, it is crucial to generate a high magnetic flux density in the powder column within the cavity. This calls for a precisely engineered magnetic circuit capable of delivering the required high flux densities.”

Coil, yoke and rectifier design

The coil, along with the power electronics that actuate it, form the core functional unit of a magnet press. There are essentially two different design versions for the coil: the transverse and the axial. As their names suggest, the field lines of the former are transversal, meaning they

run at right angles to the pressing direction, while the latter’s are axial, running parallel to it. Where the magnet geometry permits, the transverse coil is to be preferred since it allows for a slightly better alignment of the particles.

The coil’s primary function is to align the extremely small powder particles in a single direction along the magnetic field lines. Additional

tasks include providing magnetic support for the filling process and the subsequent demagnetisation, which facilitates the handling of the pressed parts.

To achieve the best particle alignment, it is crucial to generate a high magnetic flux density in the powder column within the cavity. This calls for a precisely engineered magnetic circuit capable of delivering the required high flux densities (Fig. 5).

DORST Technologies leverages its extensive experience in magnet production and utilises simulation tools to optimise coil design. The company collaborates closely with production and development partners due to the deep knowledge required in power electronics, cooling, and coil manufacturing (power electronics are based on state-of-the-art technology, ensuring safe, precise, and highly dynamic regulation of the current and, therefore, the magnetic field of the coil). The compact coils used are designed to achieve very high magnetomotive forces. Their efficient cooling provides a long service life, thereby accommodating diverse pressing and magnetising cycles.

Inert enclosure and monitoring

Depending on the material being processed, it may be necessary to remove atmospheric oxygen from the press area. Typically, oxygen content in air is around 21% at sea level, but this is too high a value for the production of NdFeB magnets, as the powder is highly reactive and can even catch fire due to oxidation. Therefore, the amount of atmospheric oxygen must be reduced to a minimum, depending on the material and application. This is achieved by creating an inert gas atmosphere within the machine’s gas-tight safety device. Nitrogen is commonly used as a shielding gas, though noble gases such as argon are also suitable. The oxygen content is

Fig. 5 Homogeneity of a transverse field for optimal particle alignment (Courtesy DORST Technologies)

monitored in a two-step procedure using appropriate sensors, ensuring that the magnet press can only begin production once the oxygen levels have dropped below the required threshold. To reduce costs, it is important to keep the volume of exchanged air as small as possible and position the enclosure close to the press area (Fig. 6).

Gloveboxes enable the operator to reach into the enclosure through gloves, eliminating the need to open the inert enclosure for every manual intervention. Still, any operating staff must also remain protected when the press area is open or access is required. This is achieved by monitoring the atmospheric oxygen levels in the press area, admitting air and enabling the doors to be opened only after human-safe levels are reached.

Part handling, cleaning, and tool changes

Pressed magnets can be removed using various methods, starting with a magnetic pulse that demagnetises the exposed magnet to the level of individual magnetic domains – a process that doesn’t affect macroscopic grain alignment. After mechanical processing and sintering, the magnets are remagnetised. Removal methods include chutes, linear axis transfers to conveyor belts, or robotic systems such as sixaxis or Scara robots.

Residual powder is often removed magnetically, with the pressed magnets passing through an appropriate magnetic field after being extracted from the cavity. In this case, a six-axis robot is an efficient solution, combining part removal and magnetic cleaning in one process.

DORST Technologies offers simple solutions by transferring parts through an airlock to the customer’s automation system. If desired, magnets can be placed onto sintering trays or in sintering boxes right after cleaning. The company has included various solutions in its FLEXCELL programme.

“Gloveboxes enable the operator to reach into the enclosure through gloves, eliminating the need to open the inert enclosure for every manual intervention. Still, any operating staff must also remain protected when the press area is open or access is required.”

Fig. 6 Inert press enclosure and oxygen monitoring system (Courtesy DORST Technologies)

“Regulating the magnetic field in the press area supports the filling process by ensuring precise magnetic alignment of particles during compaction and the necessary demagnetisation of the pressed magnets before they are released from the cavity...”

The EP30MAG press

The EP30MAG servo-motorised CNC press is a highly flexible and innovative press with a pressing force of 30 tonnes, specifically designed for the production of permanent magnets (Fig. 7). This press opens up entirely new possibilities for the quality of the magnets, achievable

through ultra-precise regulation of a homogeneous magnetic field for powder compaction. The inert safety device is closely monitored to ensure precise control and reduced oxygen content in the press area. Regulating the magnetic field in the press area supports the filling process by ensuring precise magnetic alignment of particles

during compaction and the necessary demagnetisation of the pressed magnets before they are released from the cavity for further processing.

The press frame features a four-column design with a lateral arrangement for the removal and filling systems; a front/rear arrangement is also possible as an alternative. The press’ movable crossheads, which serve as precise locating elements for the upper and lower T-pieces, are guided along the press columns by highprecision linear systems. These T-pieces form robust connections between the crossheads and the tooling, ensuring accurate force transmission and alignment during pressing operations. The press operates with a die withdrawal system, ensuring efficient removal of the tooling after each pressing operation.

The press features three position-controlled drives, with the option of closed-loop force control on the upper main drive:

• upper main drive

• lower main drive (die)

• filler drive 1

The press is operated by a movable operator terminal. The company’s Intelligent Program Generator (IPG) supports programming to ensure maximum operator convenience. The open- and closedloop controls are achieved through two independent PC systems, with the DORST Control System (DCS) managing the closed-loop control of the axes and the DORST Visualization System (DVS) handling the visualisation.

The press includes a standard powder filling system, optimised and adaptable to each specific application. Solutions for gravimetric weighing are also available.

The parts are pressed in a homogenous, adjustable transverse field generated by two vertical coils. The coils are firmly attached to the die. The homogeneity of the generated magnetic field allows for a filling height of up to 100 mm

Fig. 7 Dorst EP30MAG press for precise permanent magnet production (Courtesy DORST Technologies)

at a standard tool installation width of 100 mm. At a compaction factor of, for example, 2.2, the pressed magnets will have a height of up to 45 mm. Any tool or material brought into a magnetic field influences this field. Simulation software is available to support customers when designing applicable tools and selecting suitable materials.

The coil’s arrangement allows the parts to be pushed off onto a chute. The magnets can also be transferred through an optional airlock to a customer automation system docked to the press. Three sides of the safety device are equipped with ‘double glove’ modules, which consist of gloves and safety locking devices that prevent the operator from reaching into the danger area, eliminating the need to open the inert safety device for routine tasks.

The press has a gas-tight press safety device that meets CE conformity standards and is suitable for an atmosphere of nitrogen (N 2). Inspection windows provide an excellent view into the machine’s interior from the operator’s side, the rear, and the sides. A separate frame outside the inert enclosure serves as a connection point for the powder storage hopper of a filling device, with the frame designed to be detached from the press using a pallet truck for setup and maintenance purposes.

The safety device is equipped with gas-tight cable bushings and media feed-throughs for the nitrogen and cooling water supply. Two redundant oxygen sensors monitor the residual percentage level of oxygen content, while an additional oxygen sensor controls the ppm range. An intake air fan enables rapid air ingress, enabling the safety device to be quickly de-inerted. Electrically actuated vent flaps allow for connection to a workshop suction or venting system, while pressure relief valves ensure a consistent setting of the overpressure.

Conclusion

DORST Technologies offers both standard and custom solutions for magnet pressing, with press forces ranging from 15-1,600 tonnes. With over forty years of experience, the company has developed a strong understanding of the various requirements of magnet production. The EP30MAG serves as a robust standard press option designed to meet a wide range of application requirements. DORST Technologies focuses on refining its systems to support consistent production while meeting rising expectations for energy efficiency and quality. This enables improved operational

performance and reduced environmental impact – priorities that align with the green revolution driving increased demand.

Authors

Roland Hering

Stephan Rasch

DORST Technologies GmbH

Contact

DORST Technologies GmbH Mittenwalder Strasse 61, D-82431 Kochel am See Germany info@dorst.de www.dorst-technologies.com

References

[1] O. Gutfleisch, I. Dirba, J. Gassmann, K. Opelt, M. Schönfeldt; Ressourceneffiziente Hochleistungspermanentmagnete für Elektromobilität und Windkraft; Hagener Symposium 2024

[2] H. Nagel, W.E. Kroenert, R. Schoemann; Uniaxial Compaction of Rare Earth Based Permanent Magnetic Powders; NKE Technical Report 1994

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Powder2Powder: A closed-loop solution for high-value metal powder recycling

As sustainability becomes a strategic imperative in advanced manufacturing, the ability to recycle high-value metal powders is critical. Amazemet’s

Powder2Powder module enables closed-loop reuse of off-specification or waste powders through plasma melting and ultrasonic atomisation. This compact system restores key powder characteristics – including sphericity, particle size distribution, and chemical uniformity – making them suitable for AM processes. Tomasz Choma explains how the technology enables manufacturers and researchers to reduce waste, lower costs, and enhance material efficiency.

Recycling has become a key pillar in the response to growing environmental pressures across global manufacturing. In advanced manufacturing sectors, where the consumption of energy and raw materials is particularly intensive, the need to conserve resources and reduce waste is no longer optional. Recycling offers a practical route to mitigate environmental impact, enabling the conversion of waste into feedstock while lowering energy use and emissions.

Titanium is a case in point. Recycling titanium scrap (depending on its form) can save up to 90% of the energy required to produce the metal from ore, offering a significant reduction in CO 2 emissions. Given the high cost and limited availability of titanium, particularly in the aerospace, medical and defence sectors, recycling is not only economically beneficial but also strategically important. It reduces the environmental burden associated with primary production, including the energy-intensive processes of mining and refining.

With the growing demand for high-performance materials and the mounting pressure on supply chains, recycling has evolved from a sustainability goal to a vital part of industrial strategy. For the metal Additive Manufacturing (AM) sector, where material integrity is essential, closed-loop recycling solutions present an opportunity to maximise

material value, minimise waste, and support a more resilient and responsible manufacturing ecosystem.

The rapid advancement of AM technologies has driven a demand for metal powders with increasingly strict specifications. Powders used in processes such as Laser Beam Powder Bed Fusion (PBFLB), Electron Beam Powder Bed

Fig. 1 Ultrasonic atomisation in Amazemet’s rePowder system (Courtesy Amazemet)

Fusion (PBF-EB), Directed Energy Deposition (DED), or Binder Jetting (BJT) must meet high standards in terms of particle size distribution, morphology, flowability, and chemical composition. However, a major challenge in our industry remains the handling of powder waste that is partially used, out of specification, or incompatible with AM process requirements. Whether it is a powder with unsuitable particle size distribution (PSD), irregular morphology, or oxidised surfaces, the inability to reuse such material often results in unnecessary waste of valuable resources.

Following the success of its ultrasonic atomisation platform, rePowder, the Amazemet team is developing a new module that extends the functionality of this system into the previously untapped area of continuous powder processing. The Powder2Powder module introduces the ability to reprocess previously unsuitable metallic powders and reatomise them using a combination of plasma heating and ultrasonic atomisation. In contrast to traditional powder recycling techniques that may only alter surface morphology or partially densify particles, this approach allows complete melting and reatomisation of the material. As a result, powders are produced with high sphericity, narrow PSD, and homogenised chemical composition, restoring their usability in advanced manufacturing processes. The process enables the use of

powder mixes for in-situ alloying and atomisation.

The foundation for this innovation lies in the rePowder platform, which is a compact ultrasonic atomisation system capable of producing spherical powder from any solid metallic feedstock. The rePowder system integrates plasma or induction melting with a vibrating sonotrode, which disintegrates molten metal into uniform droplets through ultrasonic excitation. Unlike conventional atomisation methods that require high-pressure gas and industrial facilities, ultrasonic atomisation operates with lower energy input and on a smaller scale, making it ideal for R&D and short production runs. This is particularly important when working with expensive, difficult-to-source, or reactive materials, such as titanium alloys, high-entropy alloys, or precious materials. In these cases, the ability to reuse leftover powders or off-spec fractions from previous builds can significantly reduce material waste and the overall cost of AM research.

rePowder: a multitool for powder reprocessing and research

The rePowder system is more than just an atomiser; it acts as a complete research multitool that offers an integrated approach to material processing. It supports a wide range of advanced metal processing techniques, including

“The Powder2Powder module introduces the ability to reprocess previously unsuitable metallic powders and reatomise them using a combination of plasma heating and ultrasonic atomisation.”

ultrasonic atomisation, arc melting, and suction casting. These capabilities make it an ideal platform for materials research and development, particularly for research groups exploring innovative alloys and materials for Additive Manufacturing. What sets the rePowder system apart is its modularity and flexibility. The Powder2Powder module, for instance, provides an efficient way to reprocess waste metal powders and recycle them back into usable feedstock for AM and other processes that require powder as a feedstock. As research needs evolve, the system can be easily upgraded to the full rePowder system, which includes additional features such as alternative heat sources, a welding camera, and compatibility with a broader range of feedstock types, such as automatic wire or bar feeders. This upgradeability ensures that researchers are equipped to tackle new challenges and can scale their work as the demands of their projects grow.

With rePowder, researchers can optimise the properties of metal powders by controlling particle size, morphology, and chemical composition. The system also supports rapid alloy screening, enabling researchers to test a variety of material compositions and find the optimal solution for their specific applications. Whether it’s creating novel alloys or improving existing materials, the rePowder system gives researchers the tools they need to advance materials science.

Induction ultrasonic atomisation

Induction ultrasonic atomisation is a research-oriented method suited for working with materials that have lower melting points. This includes solders, magnesium alloys, aluminium alloys, copper alloys, and precious metals such as silver and gold. In this process, the material is melted in a graphite crucible using induction heating, and the molten metal is atomised onto a vibrating sonotrode by a pressure difference. This method offers precise control over particle size, and it does not

require the preparation of special feedstock, such as bars or wires. Induction ultrasonic atomisation is particularly effective for low-melting point metals and solders, making it an efficient tool for researchers working on material characterisation and powder development.

Plasma ultrasonic atomisation

Plasma ultrasonic atomisation (PUA) uses a plasma heat source to directly melt metal on the surface of a vibrating sonotrode, which is water-cooled. This technique allows for the precise atomisation of molten metals into fine powders, which is suitable for a wide range of research applications. PUA is particularly beneficial for hightemperature and refractory metals, as it provides the necessary energy to melt materials that are difficult to process using traditional methods. It does not require special feedstock preparation, and researchers can use a variety of feedstock types for atomisation. With tight control over particle size, PUA is an essential tool for researchers exploring modified alloys, complex alloys and high- and medium-entropy materials.

Scientific foundation of ultrasonic reatomisation

The Powder2Powder system’s underlying mechanism is grounded in the physics of ultrasonic capillary wave dynamics and cavitation effects. When molten metal spreads on a vibrating sonotrode surface, high-frequency acoustic waves (typically 20-60 kHz) induce a standing wave pattern on the liquid film (as shown in Fig. 2). As the amplitude of the oscillation increases, peaks of these waves become unstable and eject droplets from the surface. The frequency and amplitude of the ultrasonic vibration govern the resulting droplet size and uniformity. Unlike high-pressure gas atomisation, ultrasonic atomisation offers low-velocity breakup with a lower risk of satellite formation and ensures near-perfect sphericity and narrow particle size distribution.

“When molten metal spreads on a vibrating sonotrode surface, highfrequency acoustic waves (typically 20-60 kHz) induce a standing wave pattern on the liquid film. As the amplitude of the oscillation increases, peaks of these waves become unstable and eject droplets from the surface.”

Fig. 2 Ultrasonic atomisation enables spherical particles with minimal satellites and tight PSD control (Courtesy Amazemet)

Comparison

with conventional powder recovery technologies

Current methods for processing outof-spec powders involve multiple, separate steps. Plasma spheroidisation ensures highly spherical particles but does not adjust particle size distribution. Recasting powders into ingots for reatomisation in Vacuum Induction Gas atomisation (VIGA) or Electrode Induction Gas atomisation (EIGA) systems is costly and time-consuming, especially for small batches. Other approaches,

such as blending powders or adding flow agents, may reduce handling issues but do not restore the core quality parameters needed for AM processes. In contrast, Powder2Powder delivers powder upscaling through melting and controlled atomisation, all within a compact lab-scale unit.

Powder storage and safety risks: urgency to recycle

Unused or rejected powders, particularly those below 20 µm in size,

pose significant hazards in AM laboratories. Their high surface-tovolume ratio accelerates oxidation, degrades flowability, and raises the risk of spontaneous combustion under improper storage. For reactive materials such as aluminium, titanium, or zirconium alloys, extended storage in ambient conditions can be dangerous. As more AM users accumulate off-spec powder over time, facilities face growing logistical and regulatory pressure to reduce on-site powder inventories. Powder2Powder addresses this risk by converting hazardous leftovers into safe, flowable material ready for reuse or immediate processing.

Modular platform: from materials discovery to sustainability research

Powder2Powder is not a standalone machine. It is a module within Amazemet’s broader materials development ecosystem. When combined with rePowder, it enables closed-loop research workflows: researchers can produce alloys, build test parts, recover scrap or unused powder, and reatomise it for the next iteration. This modularity supports rapid alloy screening, parametric studies of powder degradation and reuse, and the development of circular economy strategies. It also provides a low-barrier entry point for research groups and companies focused on strategic metals or sustainability.

“Powder2Powder

is not a standalone machine. It is a module within Amazemet’s broader materials development ecosystem. When combined with rePowder, it enables closed-loop research workflows: researchers can produce alloys, build test parts, recover scrap or unused powder, and reatomise it for the next iteration.”

Enabling the future of strategic materials management

In the context of increasing global interest in supply chain security and critical raw materials, technologies like Powder2Powder play a key role. Refractory and strategic metals such as tantalum, niobium, hafnium, or rare-earth-containing alloys are often produced in limited quantities. Their powders are costly, and waste is unacceptable in both economic and geopolitical terms. Powder2Powder maximises the utility of feedstock materials, empowering high-tech industries to reduce dependency on external sources and to optimise material efficiency.

Fig. 3 Powder2Powder operates as part of Amazemet’s modular ecosystem, enabling closed-loop workflows for alloy development, powder reuse, and circular economy research (Courtesy Amazemet)

Reatomisation of Ti grade 5: reshaping what’s too big or too small

During gas atomisation, particles outside the optimal size distribution are inevitable. Oversized particles and fines generated are excluded from the feedstock. With Powder2Powder, both ends of the particle spectrum can be reprocessed.

In one test, a batch of Ti6Al4V (Ti grade 5) powder was subjected to ultrasonic reatomisation. The oversized and satellited particles (Fig. 5a), were processed into a powder with a controlled PSD range optimal for PBF-LB (Fig. 5b). Simultaneously, fines were consolidated and reatomised, eliminating the problematic fraction below 20 µ m. This approach not only recovers more than 80% of the waste as a usable powder but also dramatically reduces the flammable dust content, improving safety and storage conditions.

From blend to alloy: in situ alloying of Ti10Mo

Another powerful feature of the Powder2Powder system is its ability to create new materials from elemental powders. Using ultrasonic reatomisation, a mixture of commer -

“During gas atomisation, particles outside the optimal size distribution are inevitable. Oversized particles and fines generated are excluded from the feedstock. With Powder2Powder, both ends of the particle spectrum can be reprocessed.”

Fig. 4 Powder2Powder transforms mixed and irregular powders into spherical, size-controlled feedstock (Courtesy Amazemet)

Fig. 5 Ultrasonic reatomisation of Ti6Al4V powder: oversized and satellited particles (a) were processed into a powder with a controlled PSD optimal for PBF-LB (b) (Courtesy Amazemet)

Fig. 6. Creation of Ti10Mo alloy: a mixture of commercially pure titanium and molybdenum powders (a) was transformed into homogeneous Ti10Mo powder (b) through ultrasonic reatomisation. (c and d) show EDS/mapping for in-situ alloying (Ti-Mo) (Courtesy Amazemet)

cially pure titanium and molybdenum powders (Fig. 6a) was transformed into homogeneous Ti10Mo powder (Fig. 6b). The in situ alloying via plasma melting on the sonotrode and subsequent ultrasonic atomisation offers a streamlined pathway to generate new alloys with high throughput. This opens new possibilities in alloy development, especially for AM technologies.

Spheroidisation and reshaping of irregular particles

Not all powders are born spherical. Milled, crushed, or chemically

reduced powders, as well as irregular particles obtained from non-conventional routes, often exhibit poor flowability and are unsuitable for AM. Powder2Powder solves this by feeding such irregularly shaped materials into its plasma-heated ultrasonic system. In one test, irregular particles obtained by a chemical reduction were reprocessed. The result was a narrow distribution of spherical particles, optimised for Laser Powder Bed Fusion or Electron Beam Melting. This transformation, achieved in a single-step process,

“In one test, irregular particles obtained by a chemical reduction were reprocessed. The result was a narrow distribution of spherical particles, optimised for Laser Powder Bed Fusion or Electron Beam Melting.”

eliminates the need for separate spheroidisation and classification equipment.

Patents and Intellectual Property

Amazemet’s innovations in ultrasonic atomisation and powder recycling are protected by an extensive patent portfolio. The company holds over fifteen patents and patent applications worldwide, covering core technologies such as ultrasonic atomisation, sonotrode design, and powder reprocessing. This includes intellectual property related to the Powder2Powder concept.

Powder reprocessing reimagined

The Powder2Powder module integrates a high-energy plasma torch for localised melting and a vibrating sonotrode for ultrasonic dispersion, enabling the reprocessing of a wide range of feedstocks. These include powders, crushed components,

“In metal Additive Manufacturing, where material quality and consistency are paramount, the ability to reprocess otherwise waste material into usable feedstock presents clear benefits.”

fines, spatter, and pre-alloyed or elemental blends up to 500 µm. Compared to conventional methods such as plasma spheroidisation or gas atomisation, the process offers advantages including lower energy consumption, a narrower particle size distribution, improved sphericity, and a high yield – up to 95% usable powder per cycle.

In metal Additive Manufacturing, where material quality and consistency are paramount, the ability to

reprocess otherwise waste material into usable feedstock presents clear benefits. For industries that depend on strategic or high-cost materials (such as aerospace, medical, and defence), this approach supports both economic efficiency and environmental responsibility.

As our sector places greater emphasis on material circularity and resource resilience, solutions such as Powder2Powder demonstrate a practical path forward.

By enabling the production of high-quality powder from recycled sources, and supporting the creation of novel or hard-to-source alloys, this technology contributes to a more sustainable and adaptable AM value chain.

Author Tomasz Choma

Application Engineer

Amazemet

al. Jana Pawła II 27, 00-867 Warszawa Poland

www.amazemet.com

Fig. 7 Atomisation of TiMo alloy using Powder2Powder technology: (a) feedstock material; (b) atomised TiMo alloy; (c) particle size distribution; (d) sphericity (Courtesy Amazemet)

55,000+

Reducing defects and energy use in Hot Isostatic Pressing: A datadriven approach to degassing

In Hot Isostatic Pressing (HIP), the presence of residual gases in powder feedstocks can lead to costly defects and inefficiencies. Traditional degassing methods often rely on imprecise, time-consuming protocols that consume excess energy while failing to guarantee quality. This article introduces a data-driven solution: Gencoa Ltd’s Optix system, which uses remote plasma optical emission spectroscopy (RPOES) to enable real-time monitoring of gas species. By bringing precision and traceability to degassing, Optix helps manufacturers reduce defects, shorten cycles, and cut energy consumption.

In the production of near-net-shape parts by the Powder Metallurgy Hot Isostatic Pressing (PM-HIP) process, the meticulous optimisation of preparatory processes is essential for producing highperformance components with consistent mechanical properties and structural integrity. HIP, which involves subjecting materials to simultaneous high temperatures (typically 900–1,250°C) and isostatic pressures (100–200 MPa) within a pressurised gas environment, enables the manufacture of large, homogeneous, near-net-shape components. However, the presence of residual adsorbates – such as moisture, hydrocarbons, or trapped gases – in the powder feedstock can lead to defects such as porosity, microcracks, or delamination during HIPing. To mitigate these risks, rigorous degassing is essential prior to the HIP cycle.

Traditional degassing methods often rely on empirical protocols, such as fixed time-temperature profiles or indirect indicators such

as pressure decay rates, to estimate the removal of contaminants. However, these approaches lack precision. They frequently result in overprocessing to ensure safety margins, which consumes excessive energy and extends cycle times. Conversely, insufficient degassing leaves residual gases, compromising

component quality and necessitating costly rework. This inefficiency highlights the need for advanced monitoring systems capable of realtime, data-driven decision-making.

Gencoa’s Optix system addresses these challenges by integrating remote plasma optical emission spectroscopy (RPOES) into HIPing

Fig. 1 Gencoa’s Optix remote plasma optical emission spectroscopy (RPOES) solution can be integrated into HIP workflows (Courtesy Gencoa Ltd)

workflows. This technology excites gas molecules within a small remote ‘sensing’ device using a low-energy plasma, enabling real-time spectral analysis of emitted light to identify and quantify specific gas species. By continuously monitoring oxygen, hydrogen, argon or nitrogen levels, the system provides direct feedback on degassing progress, allowing operators to adjust parameters such as temperature or duration dynamically. This precision eliminates guesswork, shortens cycle times, and reduces energy consumption, while ensuring traceability through digital data logging.

Industries such as aerospace, automotive, and medical device manufacturing benefit from enhanced component reliability, reduced scrap rates, and compliance with stringent quality standards. Ultimately, the Optix system exemplifies how advanced analytics can transform traditional metallurgical processes into sustainable, high-efficiency operations.

Challenges in conventional HIP degassing: limitations and hidden powder risks

Residual gases adsorbed on powder surfaces or trapped within interstitial sites – including H 2O, O 2, Ar, and N 2 – pose a persistent threat to the structural integrity of components produced via HIPing. These gaseous contaminants act as latent defects, nucleating porosity, intergranular fissures, or microcracks during consolidation. For instance, moisture (H 2O) decomposes under high temperatures, releasing hydrogen that embrittles alloys, while trapped oxygen reacts with reactive metal powders (for example, Ti, Al) to form brittle oxide inclusions. Even inert gases such as Ar, though nonreactive, coalesce into voids under pressure, undermining fatigue resistance and fracture toughness. Such defects often manifest unpredictably, escaping detection until postprocessing inspections, necessitating costly rework or scrap.

Traditional degassing protocols, which rely on prolonged vacuum cycles (≥72 hours) at elevated temperatures, are inherently flawed. These methods lack precision, as they neither directly quantify gas desorption kinetics nor account for variations in powder morphology, surface area, or batch-specific adsorption behaviour. For example, finer powders with higher surfaceto-volume ratios retain adsorbed gases more tenaciously, requiring tailored evacuation parameters. However, without real-time monitoring of gas evolution rates, processors default to excessively conservative protocols, overprocessing materials to mitigate risk. This not only escalates energy consumption and cycle times but also risks altering powder characteristics, such as inducing unintended sintering or surface oxidation, which may further degrade final properties.

Inclusions in metal powders

Beyond gaseous contaminants, solid or liquid inclusions – such as oxides, carbides, or foreign particulates introduced during powder production – exacerbate HIPing challenges. Often missed during sieving or blending, these inclusions act as stress concentrators during densification. Such inclusions may chemically interact with residual gases: carbide-rich regions, for instance, can catalyse methane formation from residual carbon and hydrogen, generating high-pressure gas pockets that amplify porosity.

Systemic gaps in process diagnostics

The absence of in-situ diagnostics compounds these issues. Conventional HIPing systems lack integrated sensors to track gas species evolution during degassing. This blind spot allows systemic anomalies, such as vacuum leaks or batch-to-batch powder variability, to go undetected until post-HIPing analysis. For instance, a marginal leak introducing trace oxygen during a cycle might oxidise

Fig. 2 The Optix system: a versatile instrument for rapid gas sensing in vacuum environments, designed to operate across a wide pressure range without the need for differential pumping (Courtesy Gencoa Ltd)

sensitive powders, transforming a high-strength alloy into a brittle, oxygen-contaminated matrix. Similarly, inconsistent powder batches – common in recycled or blended feedstocks – exhibit divergent degassing behaviours, leading to sporadic quality deviations. Without real-time data, manufacturers cannot dynamically

guaranteeing defect suppression, while undetected inclusions interact with residual gases to magnify

Optix employs high-resolution optical emission spectroscopy to monitor partial pressures of gasphase species during degassing. The system’s analytical framework is based on the detection of characteristic emission wavelengths, for example, hydroxyl radicals (OH) (306–310 nm, indicative of H 2O), nitrogen (746 nm), and oxygen (777 nm).

This spectroscopic methodology enables continuous, non-invasive monitoring, avoiding issues related to the mechanical fragility and pressure limitations of quadrupole mass spectrometers (QMS). Key advancements include:

“Until advancements in in-situ gas analytics are adopted, HIPing will remain vulnerable to costly, unpredictable quality losses.

Addressing these challenges demands a paradigm shift toward innovative, datadriven degassing frameworks...”

Fig. 3 The Optix detection process (Courtesy Gencoa Ltd)

“By enabling real-time monitoring of outgassing, Optix shortens degassing cycles (the process of removing residual gases before HIPing), which in turn reduces power consumption. For example, vacuum power pump usage can be cut by 15–30 kWh per cycle.”

Real-time desorption kinetics and endpoint determination

By tracking temporal variations in gas emissions, Optix quantifies desorption rates, identifying process completion when signal intensities approach baseline levels. For instance, the decay of OH emissions correlates with H 2O removal, enabling precise endpoint detection. This potentially reduces degassing cycle times significantly, while ensuring contaminant thresholds are met.

Leak detection via gas signature analysis

During initial pump-down, Optix discriminates between ambient N 2 (indicative of air ingress) and OH (coolant or moisture leaks). Leaks are typically identified within thirty seconds of pump-down, achieving a detection sensitivity of ≤5x10 -7 mbar·l/s (helium equivalent), thereby preventing compromised cycles.

Powder quality assessment and batch traceability

Anomalous desorption profiles (for example, prolonged N 2 evolution) are linked to powder batch inconsistencies, such as improper or hygroscopic storage. Optix archives emission spectra with timestamps and process parameters, enabling retrospective batch analysis and supplier qualification.

Operational robustness and modular integration

The optical spectrometer-based detector is located in the atmosphere, outside the sensing environment, which prevents damage under all conditions. This contrasts with residual gas analysis using QMS, where the detector is located inside the vacuum and exposed to volatile species, causing filament degradation or ionisation source contamination – common failure modes in QMS systems. Additionally, traditional QMS systems are limited by a narrow operational pressure

Fig. 4 Residual water vapour with different canister exposure times (Courtesy Gencoa Ltd)

Fig. 5 Chamber leak detection (Courtesy Gencoa Ltd)

range, often requiring vacuum levels below 10 -5 mbar, which restricts their effectiveness during typical powder degassing cycles.

In contrast, Optix’s non-invasive design enables stable performance at a wide range of vacuum pressures (from 10 mbar down to 10 -7 mbar), making it uniquely suited for real-time monitoring during HIPing degas cycles without compromising accuracy or durability. This higher vacuum pressure compatibility ensures uninterrupted diagnostics throughout the degassing process, eliminating blind spots and enhancing process transparency.

Further enhancing its operational superiority, Optix’s filament-free architecture eliminates a common failure point in QMS systems. With no ionisation filaments, the system avoids degradation caused by volatile contaminants or thermal stress, ensuring exceptional longevity and minimal maintenance. Unlike QMS units, which require frequent filament replacements and recalibration, often leading to downtime and recurring costs, Optix’s robust design reduces the total cost of ownership while maximising uptime. This reliability is crucial for high-throughput industries where process interruptions directly impact productivity and profitability.

Industrial impact and process benefits

The integration of Gencoa’s Optix system delivers measurable improvements across key aspects of the Hot Isostatic Pressing workflow:

Energy savings

By enabling real-time monitoring of outgassing, Optix shortens degas -

sing cycles (the process of removing residual gases before HIPing), which in turn reduces power consumption. For example, vacuum pump power usage can be cut by 15–30 kWh per cycle.

Improved yield

Early leak detection combined with precise degas end-point detection (identifying the exact moment when gas removal is complete) helps prevent defects and lowers scrap rates.

Conclusion

G encoa’s Optix Remote Plasma Optical Emission Spectroscopy system represents a significant advancement in vacuum process monitoring, setting new standards for efficiency, precision, and reliability in Powder Metallurgy. By integrating RPOES, Optix directly addresses the critical limitations of conventional degassing methods, offering a robust, datadriven solution that aligns with the demands of Industry 4.0. The system provides essential data necessary for successful vacuum processing, including a leak check to ensure container integrity and a residual gas analysis of the species present. This robust detection method guarantees that the data provided can be relied upon, enabling intelligent decision-making and automation.

Optix delivers substantial economic benefits by enabling realtime desorption kinetics and precise endpoint detection, reducing degassing cycle times by up to 50%. For example, a facility processing ten HIP cycles weekly could save 15–30 kWh per cycle, which translates to annual energy savings exceeding

15,000 kWh – a substantial reduction in operating costs. Additionally, shorter cycles increase throughput, enabling manufacturers to process more batches without capital expansion. Early leak detection and contaminant threshold compliance further reduce scrap rates, safeguarding high-value materials such as titanium or nickel alloys from costly rework. Together, these benefits typically allow the Optix system to pay for itself within six to eighteen months, offering a swift return on investment that highlights its strong economic value.

Optix’s modular design and spectroscopic versatility also make it suitable for emerging applications, including Additive Manufacturing and ceramic sintering, where realtime contaminant control is equally vital. By combining advanced analytics with a robust, low-maintenance setup, the system supports more consistent and efficient processing. While it brings value to HIPing workflows, Optix also reflects a broader shift towards more datadriven, sustainable manufacturing practices.

Author

Dr Erik J. Cox

New Business Development Manager Gencoa Ltd 4 De Havilland Dr Liverpool L24 8RN United Kingdom sales@gencoa.com www.gencoa.com

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Happy Retirement, Chantal Labrecque!

After a distinguished career in metallurgical research and innovation, your colleagues celebrate your remarkable legacy. Since joining us in 1997, your passion, dedication, and collaborative spirit — including your meaningful contributions through MPIF — have shaped our industry and inspired those around you. Thank you, Chantal, for everything. Wishing you joy, fulfillment, and new adventures in this exciting next chapter!

With heartfelt appreciation, Your friends and colleagues at Rio Tinto