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Ultra-fine Titanium metal powder produced with new ULTRA FREQUENCY SYSTEM for Additive Manufacturing

Materials Additive Manufacturing

The race for innovation in Additive Manufacturing has a new front-runner: the ULTRA FREQUENCY SYSTEM —an advanced module for the ATO ultrasonic atomization platform, designed to meet the growing demand for ultra-fine metal powders.Traditionally, metal powders in the 20–120 µm range served most AM needs. However, as new applications in microfabrication, biomedical implants, and aerospace call for even finer resolutions, the ATO Lab Plus ecosystem has evolved. With the release of the ULTRA FREQUENCY SYSTEM, it’s now possible to consistently produce metal powders with a targeted particle size of approximately 25 μm—unlocking possibilities that were previously out of reach.

Producing spherical Niobium metal powder and High-Entropy Alloys with Ultrasonic Atomization

Materials Additive Manufacturing

Niobium metal powders are gaining momentum in advanced manufacturing, particularly in Additive Manufacturing (AM), due to their exceptional thermal stability, corrosion resistance, and superconducting properties. These attributes make niobium an excellent choice for high-performance components in aerospace, energy, medical, and electronics industries.Furthermore, niobium is increasingly used in high-entropy alloys (HEAs) — complex material systems designed for structural integrity under extreme conditions. For researchers and developers working on HEAs or reactive alloy systems, the ability to produce high-purity niobium powder in-house is a game-changer.To showcase this capability, we have produced high-quality niobium metal powder using the ATO Lab Plus ultrasonic atomizer equipped with the Single Rod Feeding System (SRFS). This demonstration highlights the precision, consistency, and material flexibility of ATO ultrasonic metal atomization technology.

Optimizing ultrasonic atomization of pure Copper and it's Alloys for Additive Manufacturing applications

Materials Metallurgy

The aim of our research was to optimize the ultrasonic atomization process of pure copper and its alloys. In this case study, we present the path of research and development (R&D) activities that we followed to achieve excellent atomization results, ensuring a high yield of perfectly spherical powder suitable for use in additive manufacturing technologies. To atomize scraps of pure copper sourced from production processes, we employed our innovative induction melting system module. By utilizing the phenomenon of magnetic induction, we melted the metal and, through a controlled pressure difference in the chamber, dosed successive portions of the molten material onto the ultrasonic system platform. This setup enabled the atomization phenomenon, producing perfectly spherical powders through ultrasound. Our study highlights the optimizations permanently implemented in our device to enhance the efficiency of the atomization process. These advancements have contributed to significant improvements in yield, precision, and quality, making the process more suitable for industrial applications. 

Aluminum zero-waste metal powder production for Additive Manufacturing

Materials Additive Manufacturing

As we move toward a more sustainable future, recycling and zero-waste processes are critical components of the circular economy. By transforming metal scraps in any form—whether from CNC machining, granulates, or irregularly shaped materials—into high-quality, reusable materials, we’re not only enhancing our technological capabilities but also supporting global sustainability goals. These innovations align with international economic objectives set at global summits, addressing both environmental and industrial needs.

Superior quality gold spherical metal powder production with Ultrasonic Metal Atomization

Materials Jewelry

Learn about process of manufacturing premium gold powder through ultrasonic atomization, a cutting-edge technique that transforms molten gold into fine, spherical particles with high purity and consistent size distribution. This method is optimized for applications in high-performance industries, including electronics, jewelry, and Additive Manufacturing, ensuring the production of top-quality gold powder with unparalleled material properties and efficiency.

Unlocking the Potential of Niobium Powder in Cold Spray & HVOF Technologies

Materials Coatings

Niobium metal powder is creating new opportunities in Cold Spray and High-Velocity Oxygen Fuel (HVOF) technologies. By utilizing ultrasonic metal atomization, manufacturers can achieve high-quality niobium powder with exceptional purity, sphericity, and optimal particle size. These features make niobium powder ideal for producing durable, corrosion-resistant coatings, which are highly beneficial in demanding industries such as aerospace and energy. This cutting-edge approach ensures high-performance surface applications that meet the evolving needs of these sectors.

Revolutionizing magnesium metal powder production with Ultrasonic Metal Atomization

Materials Additive Manufacturing

The demand for metallic magnesium powders in the 10-100 µm range is surging, fueled by innovations in the automotive, aerospace, and electronics industries. These magnesium metal powders are essential for applications requiring lightweight materials with a high strength-to-weight ratio. Magnesium's low density and excellent mechanical properties make it ideal for manufacturing lighweight components in 3D metal printing, Additive Manufacturing, powder metallurgy and other processes.

Atomized Magnesium WE43 Alloy Metal Powder for Additive Manufacturing

Materials Aerospace & aviation

In the dynamic field of Additive Manufacturing, the continuous search for materials that offer exceptional strength, durability, and lightweight characteristics is fundamental.Our recent work involves the atomization of magnesium Mg-4Y-3RE-Zr (WE43) alloy using the ATO Induction Melting System module.This process utilized material in rod form, supplied through the ATO Single Rod Feeding System, highlighting the system's capability to handle specific material forms efficiently for high-quality metal powder production.

Zero-waste dental alloy metal powder recovery from the 3D printing prosthetic scrap

Materials Medical

In contemporary manufacturing, there's a growing emphasis on reducing material losses during production processes. Through process optimization and the implementation of newer improvements, companies are actively working to minimize such losses. The ultimate goal for every manufacturing entity is to establish a closed material circulation within their processes, where all process and post-process waste is effectively reused.

AZTERLAN - Inventing surface conditioning and optimization technology

Case study Metallurgy

AZTERLAN has developed and patented a method to improve the surface of iron components. This innovative approach, targeted at improving their resistance to wear and corrosion, is named to revolutionize castings production by applying metal powders on their surface. This innovation expands the possibilities for developing high performance components manufactured using common materials. Technology is based on preparing the surface of the component (substrate) to facilitate the subsequent application of surface coatings by means of laser technologies.

FZU - Shaping the Future of Materials Science

Case study Education and Research

FZU has integrated a ATO lab-scale metal atomizer to advance its research capabilities in materials development, focusing on the production and testing of alloys such as titanium, zinc, aluminum, and high entropy alloys. This integration has improved the quality of 3D metal printing parts and enhanced FZU's participation in collaborative industrial projects and innovative materials research.

Comparison of ultrasonic and other atomization methods in metal powder production

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Explore technology of ultrasonic atomization in this insightful research paper. Learn how ultrasonic atomization outperforms traditional gas atomization in producing high-quality metal powders. With detailed analysis on particle size, density, flowability, and microstructure, this paper is a must-read for anyone interested in the future of additive manufacturing.

A Comparative Study on Laser Powder Bed Fusion of Differently Atomized 316L Stainless Steel

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The paper focuses on the advancements in Additive Manufacturing (AM) and the growing demand for small gradation metallic powders. It presents a comparative study between two methods of producing 316L stainless steel powders: Ultrasonic Atomization (UA) and Plasma Arc Gas Atomization (PAGA). The study begins by analyzing the powder particle statistical distribution, chemical composition, density, and flowability of the powders produced by both methods. Subsequently, test samples are produced using AM to observe differences in microstructure, porosity, and hardness. The study concludes with an analysis of mechanical properties, including tensile testing with Digital Image Correlation (DIC) and Charpy’s impact tests. The research finds that both ultrasonic and gas atomization methods can produce materials with similar properties, which is significant for the AM industry.

A new Al-Cu alloy for LPBF developed via ultrasonic atomization

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Discover the innovative Al-Cu alloy developed for Laser Powder Bed Fusion (LPBF) through ultrasonic atomization. This article delves into the creation of an Al-Cu alloy with additions of Ti, Cr, and Fe, designed to overcome the hot cracking susceptibility of traditional 2xxx aluminum alloys in LPBF. Learn how the addition of Ti and Cr leads to grain refinement and how near-eutectic Fe addition reduces the solidification temperature range, inhibiting hot cracking. With high nanohardness values, this novel alloy holds promise for advanced manufacturing applications.

Flexible Powder Production for Additive Manufacturing of Refractory Metal-Based Alloys

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Discover the intricacies of metal powder production for additive manufacturing with our in-depth article. Dive into the innovative ultrasonic atomization (UA) process that offers flexibility in alloy composition and is ideal for producing refractory metal-based alloys. Compare it with the industrial electrode induction gas atomization (EIGA) process, and explore how these methods affect the size distribution, sphericity, microstructure, and chemical composition of the powders. This article is a treasure trove for those keen on understanding the cutting-edge technologies in powder production for additive manufacturing.

Titanium Grade 5 atomized metal powder analysis

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Titanium Grade 5 powder atomized with our ATO Lab Plus ultrasonic metal atomizer.Access the Titanium Grade 5 Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Stainless Steel 316L atomized metal powder analysis

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Stainless Steel 316L powder atomized with our ATO Lab Plus ultrasonic metal atomizer.Access the Stainless Steel Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Inconel 625 atomized metal powder analysis

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Inconel 625 powder atomized with our ATO Lab Plus ultrasonic metal atomizer.Access the Inconel 625 Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Aluminum 4047 atomized metal powder analysis

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Aluminum 4047 powder atomized with our ATO Lab Plus ultrasonic metal atomizer.Access the Aluminum 4047 Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Heat Treatment Effect on SLM Printed Al-Si12 Using Ultrasonically Atomized Powder

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Additive manufacturing has evolved in recent years, gaining research interest from various industries. It became an important aspect of modern manufacturing since it enabled the production of the parts that were previously difficult to create. Laser-based additive manufacturing, such as selective laser melting (SLM), requires high-quality powder as feedstock. The properties of the powder can directly influence the quality of the printed part. Therefore, powder atomization has also gained attention in research society. Other than that, laser-based additive manufacturing involves high cooling rates that can result in residual stresses. Hence, stress relief heat treatment is required to avoid the warping of the part. However, heat treatment can significantly change the microstructure of the asbuilt part. Therefore, the quality and the final mechanical properties of the additively manufactured part are linked not only to the SLM parameters but also to the powder atomization and heat treatment. The influence of the printed part of both processes is still not fully understood. Hence, to study the effect of stress relief annealing on the additively manufactured material, the samples were tested on the tensile testing machine. For the printer feedstock material, Al-Si12 powder was produced on a laboratory scale using an ultrasonic atomizer. The produced powder was studied and observed under an SEM microscope. The morphology and particle size distribution were presented. The as-built samples from the atomized powder had tensile strength of 422 MPa. It was shown that heat treatment could significantly decrease the tensile strength, ultimate strain, toughness, and yield stress compared to the as-built samples. 

Magnesium WE43 - ATO Material Report

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Magnesium (WE43) powder atomized with our ATO Lab Plus ultrasonic metal atomizer.Access the Magnesium (WE43) Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Nickel-based superalloy atomized metal powder analysis

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of nickel-based superalloy powder atomized with our ATO Lab Plus ultrasonic metal atomizer.Access the nickel-based superalloy Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Magnesium ZX00 Metal Powder Material Report from ATO Induction Melting System

MATERIAL REPORT DOWNLOAD PDF

This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Magnesium (ZX00) powder atomized with ATO Induction Melting System module for ATO Lab Plus ultrasonic metal atomizer.Access the Magnesium (ZX00) Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

ATO Lab Plus ultrasonic metal atomizer brochure

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The ATO Lab Plus is a state-of-the-art lab-size ultrasonic metal powder atomizer, perfect for producing high-quality spherical metal powders for Additive Manufacturing and powder metallurgy. Its compact design, innovative technology, and customizable modules ensure efficient and cost-effective powder production.

ATO Noble precious metals ultrasonic atomizer

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Introducing ATO Noble, a groundbreaking solution designed to produce high-quality metal powders from precious metals like gold, silver, platinum, and palladium. With its advanced ultrasonic atomization system, ATO Noble ensures maximum material recovery and superior powder quality, making it the perfect tool for industries that rely on high-performance materials.

Niobium atomized metal powder analysis

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis and SEM images of Niobium powder atomized with our ATO Lab Plus ultrasonic metal atomizer.Access the Niobium Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Gold (Au) ultrasonic atomized metal powder analysis

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Gold metal powder atomized with our ATO Lab Plus ultrasonic metal atomizer on Induction Melting System module.Access the Au Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Haynes® 282® atomized metal powder analysis

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Haynes® 282® atomized with our ATO Lab Plus ultrasonic metal atomizer.Access the Haynes® 282® Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

ATO Sieve ultrasonic metal powder sieving station

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Ensures powder integrity by sieving under inert gas conditions. Equipped with ultrasonic vibration technology for high throughput and clog prevention, enhancing the quality of final 3D metal prints.

ATO Cast induction vacuum casting furnace

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Design custom castings from a variety of alloys in an inert gas atmosphere. Ideal for producing high-purity rods for atomization, enabling sustainable metal powder recovery from scraps or leftover powders.

ATO Clean ultrasonic cleaning station for atomizer components

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Facilitates quick, hands-free cleaning of atomizer components to prevent cross-contamination, supporting seamless transitions between materials and faster innovation cycles.

ATO Wipe feedstock ultrasonic cleaning station

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Compact system combining ultrasonic technology and brushes for cleaning feedstocks, ensuring maximum purity of wires and rods for superior metal powder quality.

ATO Remote Control for ATO atomizers

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Streamline atomizer operations with real-time remote control, minimizing manual intervention and boosting efficiency during metal powder production.

ATO Induction Melting System ultrasonic metal atomizer

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A versatile ultrasonic metal atomization module enabling the induction melting of reactive and non-reactive metals, supporting sustainable metal powder recovery from 3D printing scraps. Compatible with various feedstocks for unparalleled flexibility.

Aluminum 4047 metal powder atomized on IMS

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Aluminum 4047 powder atomized with our ATO Induction Melting Sysytem ultrasonic metal atomizer on HIGH ultrasonic frequency module.Access the Aluminum 4047 Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Aluminum 6060 metal powder atomized on IMS

MATERIAL REPORT DOWNLOAD PDF

This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Aluminum 6060 powder atomized with our ATO Induction Melting Sysytem ultrasonic metal atomizer.Access the Aluminum 6060 Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Pure copper metal powder atomized on IMS analysis

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Pure Copper powder atomized on ATO Induction Melting Sysytem ultrasonic metal atomizer.Access the Copper Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Copper metal powder atomized from scrap on IMS analysis

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Copper powder atomized in scrap form on ATO Induction Melting Sysytem ultrasonic metal atomizer with crucible melting method.Access the Copper Scrap Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Incusil® ABA® metal powder atomized on IMS analysis

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Incusil® ABA® powder atomized with our ATO Induction Melting Sysytem ultrasonic metal atomizer.Access the Incusil Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Bronze metal powder atomized on IMS analysis

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This material report is prepared to share with you ATO Technology powders quality and provide detailed analysis of Bronze powder atomized with our ATO Induction Melting Sysytem ultrasonic metal atomizer.Access the Incusil Material Analysis to comprehend why powders manufactured with ATO Technology represent the forefront of materials for Additive Manufacturing. Advance your manufacturing capabilities by utilizing materials that redefine industry benchmarks for quality and performance.

Niobium metal powder atomized from rods on ATO Lab Plus analysis

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This material report presents a detailed analysis of high-quality niobium metal powder atomized from rod feedstock using the ATO Lab Plus ultrasonic metal atomizer and Single Rod Feeding System (SRFS). The powder was produced under inert gas conditions using ATO’s standard frequency module, optimized for high-melting-point materials.Review particle morphology to understand how ATO ultrasonic metal atomization technology sets a new standard for metal powder solutions tailored to reactive and high-temperature alloys.

Niobium metal powder atomized from wire on ATO Lab Plus analysis

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This report delivers comprehensive material data for niobium metal powder atomized from high-purity wire using the ATO Lab Plus ultrasonic metal atomizer. The process highlights the system’s precision in converting niobium wire into uniform, spherical powder—ideal for advanced Additive Manufacturing and high entropy alloy development.Review particle morphology to understand how ATO ultrasonic metal atomization technology sets a new standard for metal powder solutions tailored to reactive and high-temperature alloys.

Titanium fine metal powder atomized with ULTRA FREQUENCY SYSTEM module on ATO Lab Plus

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This report delivers comprehensive material data for titanium metal powder atomized from wire using the ATO Lab Plus ultrasonic metal atomizer and ULTRA FREQUENCY SYSTEM. The process highlights the system’s precision in converting Ti wire into uniform, spherical powder—ideal for advanced Additive Manufacturing and beyond.Review particle morphology to understand how ATO ultrasonic metal atomization technology sets a new standard for metal powder solutions tailored to reactive and high-temperature alloys.

DED Powder Modification for Single-Layer Coatings on High-Strength Steels

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In the design of L-DED (laser-directed energy deposition) cladding processes, the chemical composition of the metallic powders is typically assumed to match that of the intended coating. However, during the deposition of the first layer, dilution with the substrate alters the weld metal composition, deviating from the nominal powder chemistry. Although the application of multiple layers can gradually reduce this dilution effect, it introduces additional complexity and processing time. This study proposes an alternative strategy to counteract substrate dilution from the very first deposited layer, eliminating the need for multilayer coatings. Specifically, to achieve a corrosion-resistant monolayer of AISI 316L stainless steel on a high-strength, quenched-and-tempered AISI 4140 steel substrate, a dilution-compensating alloy powder is added to the standard AISI 316L feedstock. Single-layer coatings, both with and without compensation, were evaluated in terms of chemical composition, microstructure, and corrosion resistance. The results show that unmodified coatings suffered a chromium depletion of approximately 2 wt.%, leading to a reduced pitting potential of Ep = 725 ± 6 mV in synthetic seawater. In contrast, the use of the compensation alloy preserved chromium content and significantly improved corrosion resistance, achieving a pitting potential of Ep = 890 ± 9 mV.