GenX Moves Titanium Off the Batch Model

The conventional Kroll process makes titanium in batches. Each cycle requires heating the furnace, loading it, cooling it and unloading it before the next run begins. GenX applies IperionX’s patented HAMR process continuously instead, which removes that dead time.

The GenX system processed more than 500 kilograms of titanium powder across four continuous runs totaling 41 hours, averaging roughly 12 kilograms per hour. IperionX collected product from each run separately and pulled samples at random from different locations for oxygen analysis. Oxygen content determines whether titanium powder can be used in demanding applications, so those results carry weight. Seven of the eight angular powder samples met the Grade 5 oxygen limit of 0.200% that applies to Ti-6Al-4V plate and bar under ASTM B265 and B348, and four of the eight also cleared the tighter Grade 23 limit of 0.130%. Every spherical powder sample met Grade 23, and therefore Grade 5 as well. One angular sample was excluded because its furnace run was interrupted before the HAMR cycle completed.

The Measured Savings Sit in Magnesium, Hydrogen and Power

Measured against the batch HAMR system already running in Virginia, GenX used more than 45% less magnesium and more than 60% less hydrogen per kilogram of titanium powder. Power consumption fell by more than 75%. Throughput, on a like-for-like run time basis, was six times higher.

Magnesium matters most among those figures because it is the largest reagent cost in the HAMR process. Using less of it also shrinks the by-product stream that requires downstream leaching and handling, a secondary saving the company plans to quantify in further campaigns. Meanwhile, continuous operation improves equipment utilization and removes ancillary process steps, which points toward lower installed capital per ton of annual capacity. Chief Executive Officer Taso Arima said that achieving continuous primary titanium production has long been the ultimate aspiration for the titanium industry, and that the first results exceeded expectations.

Scale Work Runs Through the Fourth Quarter

Through the fourth quarter of 2026, IperionX will keep optimizing the current furnace, integrate it into a full titanium powder production line, and run technoeconomic and engineering evaluation for a first industrial-scale GenX line. For scale context, comparable industrial furnace types already in service handle throughputs measured in thousands of tons per year per unit, against the roughly 12 kilograms per hour the validation runs averaged.

Importantly, GenX is not a prerequisite for the company’s existing plans. IperionX describes it as a high capacity, low cost development platform that is not required to achieve low cost production for the current 200 tonne per year production ramp or the planned expansions in Virginia. The technology therefore represents upside to the base case rather than a dependency within it. GenX also runs alongside continuous HSPT development, which U.S. Army Task Order 2 funds. That task order, awarded on August 31, 2026 under the company’s US$99 million SBIR Phase III contract, covers a continuous HSPT development furnace plus industrial-scale continuous HSPT and dehydrogenation capacity in Virginia.

Strategic Investment Summary

• Validation Complete: IperionX (NASDAQ: IPX) validated GenX across four continuous production campaigns on a commercial-scale system, processing more than 500 kilograms of titanium powder over 41 hours at roughly 12 kilograms per hour.
• Oxygen Specifications Met: Every spherical powder sample met the Grade 23 oxygen limit of 0.130%, and seven of eight angular samples met the Grade 5 limit of 0.200%, with four also meeting Grade 23.
• Input Consumption Down: Against batch HAMR, GenX used more than 45% less magnesium, more than 60% less hydrogen and more than 75% less power per kilogram of powder produced.
• Throughput Up Six Times: Continuous operation delivered six times the throughput on a like-for-like run time basis, supporting better equipment utilization and lower installed capital per ton of capacity.
• Upside, Not Dependency: IperionX states that GenX is not required for the current 200 tonne per year production ramp or the planned Virginia expansions, so the platform adds to the base case rather than underpinning it.
• Next Steps in Q4 2026: Work covers furnace optimization, integration into a full powder production line, and technoeconomic and engineering evaluation of a first industrial-scale GenX line.

Find out more about the latest operational updates and financial reports at the IperionX investor center.

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