Skyrora leads on ESA’s GSTP to develop Tanbium

Image courtesy Skyrora

The project will focus on additive manufacturing (3D printing) Tanbium, a novel high-temperature metal. Developed in collaboration with Metalysis, a UK-based specialist in bespoke metal powder production and Thermo-Calc Solutions, a service provider in the field of Integrated Computational Materials Engineering (ICME) and computational alloy design, the project aims to validate Tanbium’s production and performance for use in rocket engine components and other extreme-environment applications.  

Existing aerospace alloys often limit performance or face supply chain risks. Tanbium is a new alloy developed to overcome these challenges and surpass legacy aerospace materials, such as C103 or IN718. It offers higher burn time and temperature capability, up to an estimated 30% in weight savings in engine components, up to 95% less material waste through 3D printing and the potential for a 40% reduction in total component cost. 

This project represents a first Direct Energy Deposition (DED) application, targeting rocket engine components, specifically nozzles and combustion chambers. The production of Tanbium will reduce reliance on US imports of alloys, helping to localise a key material for the UK and European industrial sector.

The nine-month ESA-funded project begins in Q4 2025 and will include 3D printing trials, material validation, mechanical testing, and business case analysis. It marks a strategic move in advancing propulsion manufacturing and will support vertical integration. Skyrora will lead integration using its proprietary Skyprint 1 and 2 Directed Energy Deposition (DED) platforms for 3D printing, with Skyprint 2 being the largest hybrid 3D printer of its kind in Europe. 

Metalysis will supply alloy powders through its patented FFC Cambridge solid-state electrochemical technology that enables low-carbon and scalable alloy synthesis and Thermo-Calc Solutions will provide alloy design and simulation, using advanced modelling to optimise Tanbium’s chemistry and performance. 

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 US for C103 alloy, which is used across aerospace propulsion. Tanbium will enable full domestic sourcing with the powder produced by Metalysis, and components printed and tested by Skyrora, which will be simulated by Thermo-Calc to optimise material behaviour before physical testing. 

"As a European launch vehicle manufacturer, not only will Tanbium align with our long-term vision for sustainable, high-performance space hardware but it will also contribute to the ESA’s Net Zero Space ambitions.”

Nitesh Shah, CEO of Metalysis, said: “Metalysis is very excited to be participating in this ESA funded project – utilising our alloy and high entropy alloy experience to produce the new alloy ‘Tanbium’, which is predicted to significantly enhance space component lifetimes. 

"Skyrora came to us as the advanced materials partner because only our solid-state process can produce such a vast range of novel alloys. We look forward to successfully completing stage 1 of this project and moving to stages 2 and 3 and so making a real impact within the space propulsion market”.

Ida Berglund, Managing Director of Thermo-Calc Solutions, said: “Tanbium represents a major advancement in high-temperature alloy technology for space propulsion.Developed through an ICME-led design approach, Tanbium delivers performance and manufacturability gains that were previously out of reach, offering extended burn life, higher operating temperatures and significant weight and cost reductions. 

"Its validation in rocket engine components marks a key milestone, demonstrating both the maturity of ICME and the potential to secure a high-performance materials supply chain for Europe. We’re proud to see this breakthrough tested by such an experienced and forward-thinking partner alongside expert powder producers—an ideal team to showcase what Tanbium can achieve in rocket propulsion systems.”

Simon Hyde, Technical Officer at ESA, said: “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 direct energy deposition additive manufacturing. 

"Using this Tanbium alloy, the consortium are addressing a critical challenge for ultra-high temperature applications in Europe. They are opening a potentially rich seam for space applications and providing Europe with a resilient supply chain.”