British rocket and space technology firm
Skyrora has taken a leading role in a new European Space Agency (ESA) initiative under the General Support Technology Programme (GSTP). The project centres on the development and validation of Tanbium, a novel high-temperature alloy designed for additive manufacturing (AM) applications in extreme environments, particularly rocket engine components.
Tanbium is the result of a collaboration between Skyrora,
Metalysis (a UK-based specialist in bespoke metal powder production), and
Thermo-Calc Solutions, a leader in Integrated Computational Materials Engineering (ICME) and alloy simulation. Together, the consortium aims to push the boundaries of aerospace materials, addressing long-standing limitations in performance and supply chain resilience.
Localisation of supply chainsUnlike legacy aerospace alloys such as C103 or IN718, Tanbium promises significant advantages. It offers extended burn time and higher temperature tolerance, with up to 30% weight savings in engine components. The alloy also enables up to 95% less material waste through 3-D printing and could reduce total component costs by as much as 40%. This marks the first Direct Energy Deposition (DED) application of Tanbium, with a focus on rocket nozzles and combustion chambers. Crucially, the alloy’s development supports the localisation of supply chains, reducing reliance on US imports and strengthening the UK and European industrial base.
The ESA-funded project, set to run for nine months starting before the end of the year, will include 3-D printing trials, material validation, mechanical testing, and a full business case analysis. Skyrora will spearhead the integration using its proprietary Skyprint 1 and 2 platforms, with Skyprint 2 recognised as the largest hybrid 3-D printer of its kind in Europe.
Metalysis will supply the alloy powders using its patented FFC Cambridge solid-state electrochemical process, known for its low-carbon and scalable synthesis capabilities. Thermo-Calc Solutions will contribute advanced alloy design and simulation, optimising Tanbium’s chemistry and performance through ICME methodologies.
Derek Harris, director of business development and communications at Skyrora, said: “This project reinforces Skyrora’s commitment to sovereign launch capability and materials innovation. The UK and Europe are currently heavily dependent on the USA for C103 alloy, which is used across aerospace propulsion. Tanbium will enable full domestic sourcing with the powder produced by Metalysis, and components 3-D printed and tested by Skyrora, which will be simulated by Thermo-Calc to optimise material behaviour before physical testing. As a European launch vehicle manufacturer, not only will Tanbium align with our long-term vision for sustainable, high-performance space hardware, but it will also contribute to ESA’s ‘net zero’ space ambitions.”
Metalysis CEO Nitesh Shah added: “Skyrora came to us as the advanced materials partner because only our solid-state process can produce such a vast range of novel alloys. We look forward to successfully completing stage 1 of this project and moving to stages 2 and 3, and so making a real impact within the space propulsion market.”