How humans alloy metals has stayed largely the same since Bronze Age times. But a startup called Foundation Alloy is shaking things up with a new technique that beats metal powder together rather than melting it.

The company’s CEO Jake Guglin claims their process can create properties other metallurgists can’t achieve, and they are already piloting projects with automotive, aerospace, semiconductor, defense industries, as well as luxury knife makers and watch brands. Their technology could potentially make materials that withstand both heat and mechanical stress simultaneously, solving age-old trade-offs.

Foundation Alloy has raised $22 million to scale up production, aiming for several tons per week by 2027. By avoiding the traditional melting process, they claim their solid-state method uses around an order of magnitude less energy, making it more environmentally friendly too.

The key difference lies in achieving a perfect molecular-scale crystalline structure that is both homogeneous and resistant to voids, something traditional alloying can’t quite master due to differences in metal melting points. This could be revolutionary for industries where materials need to endure extreme conditions or high stress levels.