PyroGenesis confirms completion of installation of 4.5 MW plasma torch system at U.S. defence and aeronautics research facility

PyroGenesis Inc., a leader in ultra-high temperature processes and engineering innovation, and a plasma-based technology provider to heavy industry & defence, today confirmed that installation of the Company's 4.5 MW plasma torch system for a U.S. defence and aeronautics research facility, has been completed. The system and its auxiliary components are now undergoing final adjustments to ensure specification compliance.

As announced previously, PyroGenesis signed a contract valued at approximately $4.13 million (US$3.13 million) with a U.S. corporation who regularly serves as a prime contractor for the U.S. government as well as for public and private customers in the aeronautics and related industries. The contract is for the design and build of a 4.5 MW plasma torch system and related peripherals. The project is the first of two large-scale plasma torch system projects for this client, who subsequently ordered a 20 MW plasma torch, announced October 21, 2024. The 20 MW torch system, with a signed budget of $27 million (US$19.6 million), is expected to be the largest plasma torch ever produced commercially, based on the Company's own research.

The 4.5 MW plasma torch system was subsequently delivered to the client [announced January 27, 2026], pending completion of the client's facility to enable installation. Over the past few weeks, the system and related peripheral components were installed. Live pre-operational startup and testing of the plasma torch have commenced.

Once fully operational, and all specification adjustments have been completed, the plasma torch is expected to operate within an extreme-temperature test tunnel, generating the ultra-high-temperature conditions required to expose materials and scale models to extreme thermal environments and assess their performance for aeronautics applications. For reference, a 4.5 MW plasma torch is equivalent to the average concurrent electricity demand of approximately 3,750 average U.S. homes (based on an average U.S. household's continuous demand of 1.2kW).

The client is a leading centre for innovation, technology development, and testing in support of critical defence, military, and aeronautics applications. Its world-class scientific community includes internationally recognised experts whose collective contributions span numerous landmark achievements in U.S. aeronautics. The client's facilities house unique full-scale test conditions considered essential to U.S. national security.

"This announcement marks an important milestone in the deployment of our high-power plasma technology for advanced aeronautics testing," said Mr. P. Peter Pascali, President and CEO of PyroGenesis. "With the torch now installed, the system will proceed through commissioning before entering its intended operational phase, where the system is expected to support the client's specialised test programmes by providing a controlled, high-power plasma heat source capable of generating exceptionally demanding thermal conditions. This installation also represents an important step in our ongoing relationship with the client, which has already ordered a 20 MW plasma torch. The 20 MW system represents the next major scale-up in plasma power and, based on our research, is expected to be the largest plasma torch ever produced commercially."

Today's announcement complemented other advancements to the Company's high-powered plasma torch business line that the Company has previously announced. The following is a short summary of two of the more prominent projects that are currently underway:

Constellium:

As previously announced (press release dated August 5, 2025), PyroGenesis signed an industrial implementation contract with Constellium, one of the world's largest aluminium transformation and recycling companies, for the sale of plasma torch technology and related peripheral components, for use in a Constellium aluminium remelting furnace. This followed a previous announcement (press release dated April 10, 2024) detailing a collaboration agreement whereby Constellium stated its intention to use PyroGenesis plasma torches as potential replacement heating sources in Constellium's aluminium cast houses.

More recently, the Company announced [press release March 6, 2026] successful completion of the system and commencement of the delivery and installation phase.

The Company today reports that the system has been operating successfully since early June 2026 within a furnace at a Constellium manufacturing plant in France. Since that time, the furnace has been successfully producing aluminium, using PyroGenesis' plasma torch system as the furnace heat source.

The system will continue operating and producing aluminium during October, at which point the first phase of the collaboration agreement will be completed. At that point, the next phase in the collaboration agreement will be discussed between Constellium and PyroGenesis.

Norsk Hydro ASA

As previously announced (press release dated February 24, 2025), PyroGenesis signed a €1.63 million (CA$2.4 million) contract with Norsk Hydro ASA (Hydro), a Norway-based aluminium and renewable energy company that, since its founding in 1905, has become one of the largest aluminium producers in the world and one of the most respected and influential leaders in heavy industry. The contract with PyroGenesis is to test plasma technology as one of the ways to replace fossil fuels with renewable alternatives in its aluminium casthouses. This contract followed Hydro publicly announcing (in January 2024) its stated goal to achieve net-zero emissions across the entire aluminium value chain by 2050, including their intention to test plasma technology in their test centre in Sunndal Norway.

The Company today reports that the development of the plasma torch system for Hydro has been completed, and the system and related components are expected to arrive at Hydro's Sunndal facility during Q4 2026. The plasma torch system will then be installed in an aluminium furnace, with start-up and commissioning expected to be completed during Q1 2027.

Hydro's Sunndal facility is the largest and most modern primary aluminium plant in Europe. The facility, which also houses remelting, casthouse, and research and development activities, produces over 400,000 tonnes of primary aluminium, 500,000 tonnes of casthouse products, and 80,000 tonnes of anodes annually.