Copper spherical metal powder production with ATO Induction Melting System
This video demonstrates the production of high-quality copper metal powder using ATO Technology with the Induction Melting System (IMS) and a pressure-controlled crucible. The system employs ultrasonic metal atomization in a sealed, inert gas atmosphere to convert pure copper and its alloys into uniform, spherical metal powder.
The pressure-controlled crucible ensures precise molten metal flow, minimizing oxidation and enhancing material consistency. This process enables efficient, high-purity powder production optimized for Additive Manufacturing, electronic applications, and advanced material development.
Related devices
ATO Induction Melting System
Induction Melting System (IMS) is an optional and easy-to-swap module designed to increase the capabilities of the ATO ultrasonic metal atomizers.
ATO Lab
The ATO Lab Plus is a state-of-the-art ultrasonic metal powder atomizer, perfect for producing high-quality spherical powders for Additive Manufacturing and powder metallurgy. Its compact design, innovative technology, and customizable modules ensure efficient and cost-effective powder production.
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Materials
Metallurgy
Optimizing ultrasonic atomization of pure Copper and it's Alloys for Additive Manufacturing applications
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.
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Copper metal powder atomized from scrap on IMS analysis
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.
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Pure copper metal powder atomized on IMS analysis
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.
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Case study Additive ManufacturingControlled Powder Production for Advanced Research Applications - INFN INFN Gran Sasso National Laboratory (LNGS) integrated the ATO Lab ultrasonic metal atomizer into its HAMMER Hub to enable controlled, in-house metal powder production for advanced research applications. By atomizing radiopure batches and tuning particle size distribution (PSD) for PBF-LB metal Additive Manufacturing, INFN improves powder control and repeatability - measuring better powder sphericity versus commercial powders and accelerates iterative alloy development. The setup also supports INFN’s expanding materials workflow, including a new ATEX laboratory area and the IMS induction melting module for broader material routes. -
Case study Additive ManufacturingREMET - Material independence in the era of Additive Manufacturing REMET has integrated an ATO Lab ultrasonic metal atomizer to strengthen its Additive Manufacturing Metal Lab and accelerate material independence for metal 3D printing. By producing and optimizing in-house metal powders (including custom compositions and recycled feedstock), REMET improves powder quality and repeatability for demanding SLM/DMP applications. This integration expands REMET’s prototyping and validation capabilities, enabling faster iteration on advanced alloys and supporting innovative projects for aerospace, automotive, and energy industry customers. -
Materials Additive ManufacturingUltra-fine Titanium metal powder produced with new ULTRA FREQUENCY SYSTEM for 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. -
Materials Additive ManufacturingProducing spherical Niobium metal powder and High-Entropy Alloys with Ultrasonic Atomization 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. -
Materials MetallurgyOptimizing ultrasonic atomization of pure Copper and it's Alloys for Additive Manufacturing applications 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. -
Materials Additive ManufacturingAluminum zero-waste metal powder production for 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.
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