IperionX Limited has successfully validated its GenX continuous titanium production platform at its Virginia research and development facility, achieving a sixfold increase in throughput compared to conventional batch processing.

The initial four production campaigns processed over 500 kilograms of titanium powder across 41 hours of continuous operation. All valid product samples met relevant commercial oxygen benchmarks, including ASTM Grade 5 specifications for angular powder and the more stringent Grade 23 specification for spherical titanium powder.

By moving away from the repeated furnace heat-up and cool-down cycles typical of conventional Kroll titanium production and batch HAMR processing, the continuous platform delivered substantial efficiency gains. Power consumption dropped by more than 75% relative to batch operations. Reagent requirements also fell sharply, with the continuous system using over 45% less magnesium and more than 60% less hydrogen per kilogram of titanium powder produced.

“IperionX's GenX™ process is a continuous titanium production platform that is more efficient to operate and easier to scale. These first results exceeded our expectations: more than 500 kilograms of recycled titanium powder processed across four separate runs, with every sample meeting its relevant oxygen specification.”

— Taso Arima, CEO

The operating data points toward lower installed capital intensity per ton of annual capacity and reduced labor unit costs. While the company notes that GenX is not required to achieve low-cost production for its existing 200 tonnes per annum production ramp in Virginia, the platform provides a scalable expansion pathway.

The development is supported by U.S. Army Task Order 2, awarded under a US$99 million SBIR Phase III contract, which funds continuous Hydrogen Sintering and Phase Transformation furnace capacity at the Virginia facility.

“Substantially lower magnesium, hydrogen and power consumption at steady state, together with processing throughput increasing by six times, give us a strong basis for industrial development. Our next step is the engineering and economic evaluation of the first industrial-scale GenX™ production line. We aim to establish a scalable platform for expansion that lowers production costs and brings titanium within reach of a broader range of applications.”

— Taso Arima, CEO

During the fourth quarter of 2026, IperionX will continue optimizing the GenX furnace, integrate the continuous unit into a full powder production line, and advance technoeconomic and engineering work for the first industrial-scale production line.

Read the full announcement: IperionX Validates GenX Continuous Titanium Production