A team of researchers from the Max Planck Institute for Sustainable Materials has introduced a groundbreaking design concept for producing metals and alloys in a single, energy-efficient step without emitting CO2. By utilizing hydrogen as an energy source and reducing agent at a lower temperature of 700 degrees Celsius, the team has achieved a 40% energy savings compared to traditional metallurgy. The new process integrates metal extraction, alloying, and thermomechanical processing into a single reactor and step, dissolving boundaries between extractive and physical metallurgy. This one-step approach results in the production of Invar alloys with superior properties and zero CO2 emissions. The researchers faced challenges in upscaling the method for industrial applications, such as adapting to impurity-laden oxides, optimizing hydrogen use for cost-effectiveness, and potentially introducing pressing steps. Despite these challenges, the potential for this innovative process extends to exploring high-entropy alloys and utilizing metallurgical waste, promising a sustainable and resource-efficient future for metal production. The research, funded by the Alexander von Humboldt Foundation and a European Advanced Research Grant, marks a significant step towards revolutionizing metal production by offering a more environmentally friendly and energy-efficient alternative.