Introduction: Our ultrasonic atomization powder-production equipment can efficiently process raw materials of any alloy and in any form—even small sample quantities—directly yielding metal powders with uniform properties. Whether for new-material R&D or small-batch pilot production, it swiftly meets powder-production needs. The system also supports the use of virgin feedstock or recycled scrap to fabricate prototype castings and powder-based prototypes for novel alloy systems. Leveraging rePOWDER’s patented technology, it enables the resource recovery and regeneration of failed print parts, excess powder, process waste, and discarded powder, reprocessing them into high-quality fine powders. This significantly reduces material costs, boosts material utilization, and provides an efficient, environmentally friendly, integrated powder-production solution for alloy development and additive manufacturing. Ultrasonic Atomization Principle: Ultrasonic atomization is a liquid–solid separation process that uses ultrasonic vibrations to break down material into fine powder. The core principle hinges on vibration amplitude and the wettability of the material surface: when the vibration amplitude of the liquid film wetting the ultrasonic transducer exceeds a critical threshold, standing capillary waves are generated (Lierke et al., 1967); further increasing the amplitude disrupts the internal cohesive forces within the melt, causing it to be ejected as tiny droplets and ultimately forming metal powder. The particle-size distribution (PSD) can be tuned by selecting different ultrasonic frequencies: (the resulting particle size is primarily determined by the ultrasonic frequency, but is also influenced by the physical properties of the liquid material, such as density.) A frequency of 20 kHz is suitable for electron-beam melting (EBM) and direct-energy deposition (DED), producing d50 values between 80 and 100 μm depending on the atomized material. A frequency of 40 kHz is ideal for laser powder-bed fusion (LPBF) and sintering, yielding d50 sizes of 45–60 μm. A frequency of 60 kHz is best for LPBF, binder-jetting (BJ), thermal spraying, and sintering, achieving d50 values of 35–45 μm. The resulting narrow particle-size distribution allows up to 80% of the produced powder to be used in specialized processes. The rePOWDER ultrasonic atomization powder-production system can flexibly handle various forms of raw material—including wire, irregular-shaped feedstock, and long rods—and supports diverse processing routes, from wire-to-powder and powder-to-powder to manual feeding via arc melting and automated rod feeding. Ultimately, it efficiently produces high-quality metal powders with uniform particle size, providing reliable support for advanced manufacturing and material recycling. By employing state-of-the-art ultrasonic atomization technology, we can use a wide range of materials to produce high-performance, custom-made metal powders tailored to your specific requirements, ensuring optimal performance in real-world applications. The figure below shows validated material systems; additional new materials are continuously under development. Two Types of Heat Sources: ① Induction Melting: Induction melting is typically used for alloys with melting points up to 1300°C, such as: · Volatile materials with relatively low melting points that readily evaporate in plasma, including Sn, Zn, Mg, Pb, and Al alloys. · Materials with high heat capacity and high thermal conductivity, such as Cu and other precious metals like Ag and Au alloys. Any shape or form of material can be placed in the crucible, including final alloys, master alloys, or pure elements. Under the influence of magnetic stirring, all materials readily alloy together. ② Arc/Plasma Melting: Heating can be carried out in an inert or reactive atmosphere using an electric arc (TIG generator) or focused plasma. Top feeding and melting of the consumable electrode require the use of suitably designed ultrasonic electrodes to enhance their interaction with the workpiece, thereby minimizing external contamination. This method is well suited for use with all medium- and high-melting-point materials, including: · Iron-based alloys · Ti-, Ni-, Pt-, Ir-based alloys · Refractory materials such as W, Ta, V, Mo, Nb, and Re, as well as high-entropy alloys · Metal composites Core Advantages and Features: Processing of Any Element or Alloy: Ultrasonic atomization can be applied to a wide range of pure elements—from Zn and Mg to Pt, Mo, and Ta—as well as to any alloy composition, such as Mg-Li, CuSn6, TiTaZrRuCu, and others. Handling of All Forms of Raw Material: The system can atomize chips, failed additive-manufacturing prints, damaged samples, rods, wires, powders, and more. Automated Operation: Various automatic feeders—for powders, rods, and wires—and automated plasma cutters make operation as simple as possible. Modularity and Open Architecture: The rePowder platform features a modular design, allowing new modules to be added at any time. All connections within the equipment comply with current standards (e.g., ISO-KF), enabling each customer to design and connect their own modules as needed. One Device, Many Possibilities: The rePowder platform can perform multiple different types of processes using a single unit, including preparing new compositions, homogenizing alloys, ultrasonic atomization, suction casting, and other options currently under development. Multiple Alloys Produced in a Single Day: The equipment is laboratory-scale, easy to clean, and allows rapid material changes. Within a single day, different alloys can be repeatedly atomized on different ultrasonic systems. Wide Range of Applications: The resulting powder can be used in a variety of technologies, including additive manufacturing, sintering, thermal spraying, catalysis, and more. Recycling: The equipment can reprocess printed components or scrap into powder for further use in desired applications. Low Maintenance Costs: The system requires only a very small amount of inert gas—about 10 liters per minute—and the cost of a single atomization run is negligible. Depending on specific needs, multiple capacity options are available, ranging from a few grams per day (for small batches of alloys or rare, expensive elements) to several kilograms per day (when processing wire or using the induction module). Equipment Parameters: Heat Source: Induction Heat Source, Arc/Plasma Heat Source, Dual-Heat-Source System Footprint: Approximately 360 × 220 × 220 cm Power Requirements: 380 VAC, 50 Hz, three-phase, 36 A per phase 340 A at 40% load (250 A at 100% load) 380 VAC, 50 Hz, three-phase, 36 A per phase Sphericity: 0.98, no satellite particles 0.98, no satellite particles 0.98, no satellite particles Minimum Atomization Start-Up Quantity: ≤100 g ≤100 g ≤100 g Supported Materials: Includes, but is not limited to, stainless steel, high-temperature alloys, titanium alloys, platinum–iridium and platinum–rhodium alloys, and high-entropy alloys. Alloy Materials: Includes, but is not limited to, stainless steel, high-temperature alloys, titanium alloys, platinum–iridium and platinum–rhodium alloys, and high-entropy alloys. Induction Atomization Unit: Consists of an electrical cabinet, an induction furnace, an induction atomization chamber, and a collection device—an independent unit. Plasma Atomization Unit: Comprises an atomization chamber, vacuum and gas management systems, feeders, a plasma torch, transducers, vacuum manipulators, and a powder-collection container with an airlock. Induction Heat Source: Melting temperature ≥1300°C / ≥1300°C Plasma Heat Source: Temperature ≥3500°C / ≥3500°C (3) Key Advantages: · Compact footprint and simple operation · Cost savings and low inert-gas consumption · No powder adhesion to the inner walls of the atomization chamber · Rapid cleaning of the atomization chamber
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