Magnesium was used as a reductant for the direct combustion synthesis of titanium alloy particles (Ti–6Al–4V) from titanium oxide (TiO 2 ). The feed material (TiO 2 ) and reductant (Mg) were mixed with Al (or AlCl 3 ·6H 2 O), vanadium pentoxide (V 2 O 5 ), and calcium hydroxide (Ca(OH) 2 ), and the reaction mixture was combusted under pressurized argon. Temperature–time profiles were intermittently measured during combustion to analyze the combustion temperatures and wave velocities. The combustion product was subsequently acid-leached to eliminate secondary phases (MgO, MgCl 2 , CaO) and produce Ti–6Al–4V alloy particles whose oxygen content was ~1.3%. Further the content of oxygen was decreased to 0.2wt.% by deoxidizing the Ti–6Al–4V alloy particles with calcium in the range 850–900°C. The AlCl 3 ·6H 2 O affected the particle morphology more than the Al metal did; i.e. the Al-doped alloy particles were porous and consisted of relatively small agglomerated particles whereas using AlCl 3 ·6H 2 O produced dense, round particles. Pilot-scale production experiments revealed that Ti–6Al–4V alloy particles can be efficiently produced using our method.