PyroGenesis,a specialist in ultra-high-temperature processing and plasma-based engineering solutions, has delivered 3.5 tonnes of titanium powder to a U.S.-based minerals and metal technology company under a new supply agreement, using its patented NexGen plasma atomization process.
The shipment marks the first in a recurring order arrangement, providing high-quality titanium feedstock to support critical industries—from aerospace and defense to medical devices, electric vehicles, and additive manufacturing—while promoting sustainable, closed-loop production.
Off-Cut Titanium: Unlocking Hidden Value
This latest order involves “off-cut” titanium powder (Ti64), a category produced during the NexGen plasma atomization process that is not currently utilized by the standard range of industrial metal 3D printers. While not classified as prime powder, these off-cuts retain consistent chemistry and characteristics suitable for industrial alloy production.
“As the additive manufacturing market expands, the Company is well positioned to take advantage of emerging opportunities. Along with our fine and coarse cut titanium powders, we now have a market for what we define as off-cut material, which not only makes effective, sustainable use of a high-value byproduct of our NexGen process, but increases the revenue generated for each production run,” said P. Peter Pascali, President and CEO of PyroGenesis. “This contract reintroduces stockpiled high-value titanium into the supply chain, reducing waste and protecting the critical mineral supply. We look forward to this ongoing, recurring relationship with the client, an innovator in technology development for the metals and manufacturing sectors.”
This order represents one of the first commercial utilizations of PyroGenesis’ stockpiled off-cut powders and reflects growing market demand as additive manufacturing technologies evolve.
Industry Context and Strategic Importance
Titanium is classified as a critical mineral in both Canada and the U.S. due to its high strength-to-weight ratio, corrosion resistance, and essential role across high-tech industries. The global titanium powder market for additive manufacturing is projected to grow from $214 million in 2023 to $1.4 billion by 2032.
Advances in Titanium Powder Development
Alongside PyroGenesis, other industry players are also advancing material capabilities for metal additive manufacturing. U.S.-based metal 3D printer manufacturer Velo3D has announced progress in qualifying C103 niobium and Ti-6Al-4V titanium powders produced by Amaero Ltd., following the successful completion of a key testing milestone conducted by Auburn University’s National Center for Additive Manufacturing Excellence (NCAME).
Elsewhere, Renishaw has partnered with Canadian materials producer Tekna to improve the efficiency and cost profile of titanium AM through the development of a coarser-cut titanium alloy powder optimized for LPBF platforms. By increasing particle size relative to conventional fine Ti-6Al-4V powders, the approach enables faster build rates, reduces flammability and inhalation risks, and lowers material handling and infrastructure costs, addressing long-standing safety and economic challenges that have limited broader industrial adoption of titanium 3D printing.
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Featured image shows SEM image of PyroGenesis’ powders. Image via PyroGenesis
