Thermo-Calc Solutions, the specialist in Integrated Computational Materials Engineering (ICME) and alloy design, will work with Metalysis and Skyrora to test and evaluate a novel alloy for space applications. The partnership is formed as part of Skyrora’s award from the European Space Agency (ESA)’s General Support Technology Programme (GSTP).
Image courtesy of Skyrora
Addressing the Need for High Performance Materials in Europe
In response to the growing demand across the European space sector for stronger, more durable, and resource-efficient materials, a new collaboration between Metalysis, Skyrora Ltd, and Thermo-Calc Solutions AB is advancing the development and testing of Tanbium, a novel, hafnium-free tantalum-niobium (Ta-Nb) alloy. Designed by Thermo-Calc Solutions as a cost-effective alternative to legacy alloys such as C-103, Tanbium offers high-temperature stability, oxidation resistance, and performance in extreme environments, making it well suited for critical aerospace applications such as space propulsion systems.
Advancing Propulsion Manufacturing
Skyrora, a leading European launch vehicle manufacturer, is exploring Tanbium in a strategic push to advance propulsion manufacturing. This ESA GSTP-funded UK project supports vertical integration, strengthens Skyrora’s additive manufacturing (AM) leadership, and enhances supply chain resilience by reducing reliance on foreign suppliers. For the UK space sector, it fosters domestic supply chains, aligns with the National Space Strategy, promotes knowledge exchange across the value chain, and unlocks export potential for high-value technologies, reinforcing the UK’s global competitiveness in space innovation. Derek Harris, Director of Business Development and Communications, Skyrora, explains:
This project reinforces Skyrora’s commitment to sovereign launch capability and materials innovation. Tanbium’s potential to replace imported alloys aligns with our long-term vision for sustainable, high-performance space hardware.
In this nine-month effort, Metalysis, a UK leader in sustainable metal powder production, will produce Tanbium alloy powder using its solid-state process, cutting carbon emissions and supporting ESA’s Net Zero Space goals. Skyrora will print test specimens and demonstrator technological component elements via direct energy deposition (DED), evaluating performance through mechanical and high-temperature trials. Thermo-Calc Solutions AB will tailor Tanbium’s composition for Skyrora’s Launch Vehicle, using advanced ICME tools to simulate and optimize material behavior before testing. This integrated approach reduces development time, cost, and risk, while enabling rapid production and deployment of high-performance, customized materials—advancing Europe’s technological autonomy and responsive launch capabilities.
Performance Benefits through Material Innovation
One of Tanbium’s standout advantages is its compatibility with AM, enabling the creation of complex geometries not possible through conventional methods. This flexibility also allows for rapid prototyping and design iteration, dramatically reducing lead times and tooling costs, key benefits for the fast-evolving European aerospace market. Simon Hyde, ESA Technical Officer, says:
Ultra-High Temperature capable materials for rocket motor applications are a key item in the ESA work plans. This project addresses the challenge in an outstanding way; it combines bespoke alloy design with a unique production approach. These technologies are perfectly wedded to DED AM. Using this Tanbium alloy, the consortium are addressing a critical challenge for ultra-high temperature applications in Europe. They are opening a potentially rich seam for space applications and providing Europe with a resilient supply chain.
How Thermo-Calc Solutions Enables Faster Market Entry
Thermo-Calc Solution’s ICME technologies will help navigate complex material trade-offs by simulating material behavior prior to physical testing, helping reduce development time, cost, and risk, all enabling faster market entry for new products. Ida Berglund, Managing Director of Thermo-Calc Solutions, explains:
Successful deployment of Tanbium in space applications enables performance previously out of reach. With our ICME tools we can further customize Tanbium for rapid production and integration into Skyrora’s platform, reducing risk and accelerating deployment.
By combining sustainable metal production, AM, and ICME-driven development, the partnership supports the European strategic goals for innovation, competitiveness, and autonomy in space technologies, paving the way for Tanbium to be deployed in space and other high-performance industrial sectors across Europe.
For more information about this project, please contact:
Based in Stockholm, Sweden, Thermo-Calc Solutions offers specialized ICME solutions such as materials design, alloy composition- and heat treatment optimization. As the engineering services division of Thermo-Calc Software, the company serves clients globally in accelerating materials innovation through simulation and modelling.
Skyrora Ltd: Headquartered in Scotland with facilities located across Europe, Skyrora designs, manufactures, and deploys launch vehicles for small satellite manufacturers looking to access space. Skyrora’s strategy is to take an incremental ‘step-by-step’ approach to allow for critical testing and de-risking, utilising proven technology in combination with advanced additive manufacturing methods. In August 2025, Skyrora received its launch licence to commence a commercial orbital launch programme.
Metalysis is a global leader in producing metal powders, alloy powders and high entropy powders for use in advanced electronics including space, semiconductors and capacitors, defence, hypersonics, engineering and construction, aerospace, clean energy, electric vehicles, AI, 5G and the IoTs. Deploying our patented FFC solid-state electrolysis process we can reduce metal oxides from 49 elements of the periodic table creating valuable metal, metal alloy and high entropy alloy powders.
