Necessity
is the mother
of invention
ATO Lab is the answer for the needs of faster development of new metal powders.
Necessity
Materials
freedom
Accelerate process of new materials research.
Metal powder
atomizer
For the quick production of the next generation materials.
ATO Lab is an unique, compact
machine for metal powders
production, using a novel ultrasonic
atomization technology.
This breakthrough solution allows you to quickly produce free-flowing metal powders with narrow particle size distribution.
Key Features
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Highest quality powders
ATO Lab allows you to quickly produce high quality metal powders. Due to the ordered nature of the atomization process, the output powder has a very narrow particle size distribution, closely depending on the chosen ultrasound frequency. For example for a frequency of 35 kHz, 70% of 316L steel particles are in the diameter range of 40 to 60 µm
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Process flexibility
The ATO Lab configuration is flexible and based on a patent pending ultrasonic atomization technology. We will be pleased to tailor the system specifically to accommodate for individual needs of the ordering party.
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No limitations in minimum powder quantity
ATO Lab uses a roll feeding system for material delivered as a wire with virtually no limitation on minimum amount of input material. This is a huge advantage for all customers working with expensive or more unconventional raw materials.
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Wide range of alloys
Develop, test and characterize the next key metal powders in additive manufacturing, hot isostatic pressing and conventional powder metallurgy. ATO can process a wide range of alloys, both reactive and non-reactive, such as steel, aluminum, titanium and many more – even highly specialized. Perfect both for commercial and research needs.
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Compact size
ATO Lab has been designed by industry-oriented researchers aiming to overcome usable space limitations. ATO Lab has a compact form, making it possible to comfortably use even in restricted spaces. Along with its innovative technology and no requirements for sophisticated infrastructure, it ensures exceptionally low operating costs and quick return on the investment (ROI).
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Cost-effective production
Cut your costs and rapidly optimize your process with powders tailored to your commercial or research needs. In comparison with currently available atomization technologies, ATO has considerably lower media consumption. This cost-effective process is not only smooth and rapid, but also attractive from economic point of view.
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Affordable price
ATO Lab’s compact size and unique, solutions allowed 3D Lab to offer a highly competitive price for the device itself. It’s a technologically advanced and cost attractive tool for small and medium-sized companies, metal powder manufacturers and research institutions.
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Scalable system structure
ATO Lab is a modular system with the future potential to operate using sets of many units in one interconnected network.
ATO Technology
ATO Lab Technology
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The ATO Lab atomizer is a device producing metal powders using an ultrasonic atomization technology.
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The working principle of ultrasonic atomization (Fig. 1) is based on plasma arc melting of the input material, supplied in the form of wire. Next, the molten metal is subjected to vibrations with a specifically chosen frequency.
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The right vibration amplitude induces the atomization of the liquid metal, which then solidifies in the form of spherical powder.
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During the atomization process, the powder is carried by the shield gas. The desired powder is then separated in a cyclone and directed to the storage reservoir through a double lock. A specially created unit and lock system allow for powder collection during the atomization process.
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ATO Lab allows for the atomization of the majority of currently existing metal alloys with maximum melting point not higher than that of pure titanium.
Main components
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RECIRCULATION PUMP
gas-tight design keeps atmosphere oxygen-free during the process
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FILTERS
second step of particulate filtrationis designed to remove excessive fumes and allows to recirculate inert gas
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FEEDING SYSTEM
either rod- or wire-feed it is flexible option depending on the material form
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PROCESS CHAMBER designed to minimize
powder left and keep compact size of the machine
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PLASMA TORCH
efficient internal cooling designed for the longest and most demanding processes
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SONOTRODE
the very heart of the machine, build with patent pending technology and state-of-the-art nanoalloys, it provides unique process flexibility
Main components
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ULTRASONIC TRANSDUCER
the “vibration engine” brings energy necessary for melt atomization
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CONTROL SYSTEM
highest quality electronic controls machines sensors and devices, it allows for both process monitoring and analysis
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ULTRASONIC GENERATOR
powers up the transducer, advanced control system allows for full process monitoring
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CYCLONE
the element responsible for powder collection, it separates powder from inert gas
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VACCUM PUMP
removing air at the begging of the process provides exceptionally high atmosphere purity with oxygen level below 0,01 %
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PLASMA GENERATOR
robust power supply guarantees stable process while efficient IGBT inverter minimize energy loss
Atomisation
Timeline
Atomization as a technological process is understood as the spraying of various substances. Metal alloy atomization was developed to satisfy the needs of the scientific field of metallurgy.
The first known metal atomization processes using widely applied technological solutions date back to the times of the First World War. Since then, these technologies have been undergoing significant changes, which resulted in the improvement of their efficiency and versatility.
Atomized metal powders are being used in more and more branches of industry. Technological development necessitates the constant development of novel metal alloy powders. Such works have been so far severely limited by the low availability of atomizing devices due to gas and water atomizers being large in size, costly and requiring purpose-built infrastructure – all of these factors making them huge investments on their own.
The implementation of a new ultrasound technology has allowed for the enclosing of the whole atomization process in a compact device. From now, atomization can even be carried out at a laboratory scale to produce exceptionally low amounts of powder. There is no more need to use the enormous, wildly expensive atomizing sites when all you need is just a piece of your lab space!
Target
Industries
ATO Lab is a device intended for the use research in development in a range of powder metallurgy areas. Next generation ultrasonic atomizer allows for the production of exceptionally small minimal amounts of spherical powders with a very narrow particle size distribution, as well as obtaining significantly higher yields through continuous operation.
Even though the additive manufacturing field was the initial inspiration for the design of ATO Lab, the unique technology, allowing for the production of very small amounts of the output material and its high quality, the ATO powders can also be used with success in the following fields of interest:
Brazing (soldering)
ATO Lab allows for the atomization of materials with a low melting point.
Powder spraying
Thanks to its high flowability, the powder produced in ATO Lab is perfectly suitable for the use in thermal spraying.
Filters and foams
Spherical shape and narrow particle size distribution of the powders allow for the production of high quality porous and filter sintered materials.
Conventional powder metallurgy
ATO One also simplifies research on the influence of alloying additions on the properties of conventionally produced sintered metal materials.
Laser cladding
Similarly to thermal spraying, laser cladding also requires highly flowable spherical powders.
Chemical synthesis
Metallic materials are also often used as substrates in a wide range of chemical reactions. ATO Lab allows for the production of substrates with highly controlled chemical composition.
Catalysis
Metallic catalyzers are the basis of modern chemical engineering. Thanks to ATO Lab, small amounts of noble metals used in this application can be processed.
Showcases list
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8:30 Wire input and system setup
The first step involves machine calibration and setup for a specific wire diameter. The melting tip is prepared and subsystems are checked.
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9:00 First test
During the first trail, the input material is being atomized, while the operator checks for proper parameter setup. First optimization is performed.
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10:00 Powder check
Output powder is being checked under a microscope. Sphericity is measured.
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10:30 Second test and the adjustment of parameters
As before, the material is being atomized, while the processing parameters are being adjusted to best fit the specific requirements
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12:00 Production batch
After preliminary optimization, the material undergoes atomization in the first batch. About 200-500 g of raw material is being atomized, depending on the chosen material and set parameters.
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14:00 Sieving and SLM preparation
Powder is being sieved and conveyed to the SLM machine. Now, first trials can be started on an entirely new material.
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15:00 SLM test run and chamber cleaning
During the first laser melting trials, the operator is free to clean up the atomization chamber and prepare it for the next process.
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16:00 SLM test run check-up
After an hour first test-cubes made of new material can already be acquired!
Materials
While creating ATO Lab, we have come to realize that the range of metallic powders currently available on the market is severely limited and does not constitute an appropriate offer for potential consumers to choose from. Moreover, the large amounts of output powders produced with currently available technologies make them scarcely justifiable from the economic point of view of small laboratories, R&D departments or research units.
Our intensive development work aimed at the optimization of the laboratory-use atomization process has resulted in successful production of both reactive and non-reactive powders on a smaller, yet still completely self-sufficient scale.
Company
3D LAB Ltd. is a company based in Warsaw, Poland.
We have over 10 years of experience in areas such as:
– 3D printing technologies
– new materials research
– metal powders production
and AM parameters optimization.
Contact
Sales Department
Jakub Rozpendowski
T: +48 793 933 603
jakub.rozpendowski@3d-lab.pl
Mariusz Leśniak
T: +48 502 593 370
mariusz.lesniak@3d-lab.pl
Michał Deryło
T: +48 574 550 559
michal.derylo@3d-lab.pl
Office
Paulina Kusiak
T: +48 739 008 153
paulina.kusiak@3d-lab.pl
Joanna Zapolska
T: +48 535 051 366
joanna.zapolska@3d-lab.pl
Service
Paweł Wesołowski
T: +48 530 009 153
pawel.wesolowski@3d-lab.pl
Customer Support
ato-support@3d-lab.pl
Contact Us
3D LAB sp. z o.o. with its registered office in Warsaw,
address: 63B Farbiarska Str. 02-963 Warsaw, Poland,
registered with the commercial register of the National Court Register under number KRS 0000572964, VAT number PL9512396922