@HighUintas Great questions! Happy to get into it.
Yes, we did test aluminum options. The challenge is that with the irregular octagon shape of our pot, aluminum is much harder to manufacture consistently because it’s a softer material than titanium. Titanium allowed us to build the exact shape we wanted, which is what makes it possible to nest the entire cook system inside the pot.
A couple other key points on the pot itself. Our titanium pot is 900 ml, has burn free handles, and includes a silicone lined lid that stays securely in place.
On weight comparisons, our listed weights are total system weights, not just pot plus stove like most setups you’ll see online. Our total system weight is 9 oz without the windguard and 10 oz with the windguard, and that includes the stove, pot, windguard, and the 8.3 inch folding spork.
If you compare other similar sized hex systems and include everything needed to run them the same way, total weights are typically around 15 to 16 oz or more. That puts us roughly 33% to 44% lighter.
We’ve also used the same kind of ultralight “Frankenstein” setup you’re describing, and those definitely work.
In our opinion, there are a few benefits that are worth the small weight penalty compared to an ultralight titanium pot and stove setup like you mentioned. For us, that starts with a titanium pot that nests the entire system inside, so you never have to go digging through your pack to find parts. It also includes an 8.3 inch folding spork you won’t lose, burn free handles, a silicone lined lid that stays securely in place so nothing goes flying, a pot that locks onto the stove for added stability, and much better performance in windy conditions with the removable windguard.
Again, this is all personal preference, but we felt those benefits were worth it.