Powder2Powder
Enable powder recycling, significantly improving the utilization rate of additive manufacturing powders.
A fully protective atmosphere is maintained throughout the process to prevent secondary oxidation and contamination of the powder.
Low-temperature thermal regeneration repairs defects without altering the powder’s original structure.
Multi-module integration enables continuous powder processing.
Compatible with a wide range of mainstream additive manufacturing powders, with strong specificity.
Flexible operating mode and high equipment utilization.
Process parameters are controllable, and powder properties exhibit excellent consistency.
Aligns with the circular economy and reduces raw material costs.
Product Introduction
Preface:
Still struggling with unusable metal powders? Handling non‑conforming metal powders poses a host of practical challenges: process‑generated, non‑recoverable powder leads to costly waste and necessitates continuous procurement of fresh material; idle powder occupies valuable storage space and must be stored and handled under stringent safety protocols; in additive manufacturing, the use of mixed powders can compromise the quality of the final parts; moreover, non‑compliant powders are subject to regulatory and environmental compliance requirements, prohibiting their indiscriminate disposal, with complex and expensive disposal procedures. In addition, inspecting and managing residual powder consumes significant time, and if test results fail to meet specifications, re‑procurement and retesting are required, further delaying production. Today, the metal powder industry faces substantial hurdles in recycling and reuse, underscoring an urgent need for innovative, end‑to‑end solutions.
At present, the market lacks an ideal solution tailored to small- and medium‑batch metal powder recycling; existing technologies all have inherent limitations:
- Plasma spheroidization can remelt powder particles into spherical shapes using a plasma jet, thereby improving flowability, optimizing particle size distribution, and eliminating internal defects; however, it cannot alter particle size or homogenize mixed powders.
- Screening and classification can separate usable powder from non‑conforming powder based on particle size and optimize the particle size distribution, but they cannot improve flowability or remedy powder defects.
- Re‑atomization enables the remelting and re‑atomization of degraded powder, yielding qualified powder with uniform properties; it is an effective method for recovering powders with abnormal morphology. However, it is costly, energy‑intensive, and requires sophisticated equipment, making it uneconomical for small‑ to medium‑batch recycling. Moreover, repeated remelting can lead to fluctuations in alloy composition and oxidation, compromising powder performance and extending the processing cycle.
A groundbreaking solution that is disrupting the market
Powder2Powder is a laboratory‑scale system developed by AMAZEMET specifically for the regeneration and modification of metal powders. Targeting the needs of metal additive manufacturing—namely, powder recycling and performance optimization—it offers a comprehensive solution for the “recycling–regeneration–modification” of metal powders. Leveraging the brand’s deep technical expertise in ultrasonic atomization and materials processing, it provides robust hardware support for both powder reuse and enhanced material properties. The equipment enables the recovery and regeneration of waste and residual powders generated during additive manufacturing, while also allowing for the performance‑based modification and optimization of regenerated or newly produced powders. This boosts the utilization rate of metal powders, reduces raw‑material costs in additive manufacturing, and aligns with the principles of sustainable development and the circular economy. Powder2Powder features a compact, laboratory‑grade design, making it well suited to research institutions and additive‑manufacturing companies for both lab‑scale experimentation and small‑batch production. It can handle a wide range of common metal powders used in additive manufacturing, including iron‑based, titanium‑based, aluminum‑based, and nickel‑based varieties, and tailors dedicated regeneration and modification processes to the specific characteristics of each powder type. The core functions of the system revolve around powder purification, regeneration, and modification: it effectively removes impurities, oxide layers, and large‑size agglomerates from waste powders, restoring their original properties. At the same time, it can perform targeted modifications such as particle‑size optimization, surface repair, and compositional fine‑tuning, enabling regenerated powders to achieve performance levels that meet or even approach those of freshly produced powders; certain modified powders can even exhibit further, application‑specific enhancements. The system has been successfully deployed across numerous additive‑manufacturing firms and research institutions, facilitating the circular use of metal powders. In practical applications, it helps raise the overall powder utilization rate in metal additive manufacturing to significantly higher levels. Moreover, its user‑friendly operation and precise control over process parameters allow for flexible adjustments to regeneration and modification protocols based on the degree of contamination and specific performance requirements, thereby providing critical technical support for the green development of metal additive manufacturing.
Working principle:
The core operating principle of Powder2Powder is based on physical purification, thermal regeneration, and precision modification of powders. The overall process is divided into five key stages: powder feeding and pre‑treatment, impurity removal and purification, thermal regeneration, performance modification, and graded collection of the finished product. Each stage is implemented via dedicated process modules to enable continuous operation, with all steps carried out under a controlled protective atmosphere to prevent secondary oxidation and contamination during processing. First, waste powder, residual powder, or freshly produced powder is fed into the system through a metering module and enters the pre‑treatment sub‑module. Low‑speed stirring combined with air‑flow dispersion breaks up particle agglomerates, yielding a uniformly dispersed powder state. Simultaneously, magnetic separation removes ferromagnetic contaminants, completing the initial pre‑treatment. Depending on the powder’s initial condition, the stirring speed and air‑flow intensity can be adjusted to accommodate varying degrees of agglomeration. Subsequently, the pre‑treated powder moves to the purification and impurity‑removal module, which employs a combination of air‑classification and vacuum purging. By precisely controlling the airflow velocity, this stage achieves an initial separation of fine impurities, large agglomerates, and acceptable‑grade powder. Meanwhile, under vacuum conditions, high‑temperature purging removes surface oxide layers and adsorbed gaseous contaminants; the temperature and duration of this step can be tailored to the powder’s material properties, ensuring effective oxide removal without altering its intrinsic microstructure. Next, the purified powder proceeds to the thermal regeneration module, where it undergoes low‑temperature sintering in a protective atmosphere. Through precise control of temperature and dwell time, surface microdefects introduced during additive manufacturing are repaired, while the powder’s sphericity is slightly optimized, restoring its flowability and powder‑spreading characteristics. The heating temperature in this stage remains well below the powder’s melting point, preventing melt‑induced agglomeration and preserving the original particle size distribution. If performance modification is required, the regenerated powder is directed to the performance‑modification module, which offers three core functions—particle‑size optimization, surface repair, and compositional fine‑tuning—according to specific needs. Particle‑size optimization is achieved via precise air‑classification; surface repair involves vapor‑phase deposition to form a thin coating that repairs surface defects; and compositional fine‑tuning uses accurate powder blending to uniformly incorporate trace elements, thereby optimizing the powder’s composition and performance. Finally, the regenerated or modified powder enters the finished‑product grading and collection module, where multi‑stage air classification enables precise separation and collection of powders across different size ranges. Depending on the requirements of the additive‑manufacturing process, powders within a specified particle‑size range can be collected as finished products. The entire process is continuous and stable, with all process parameters independently and precisely adjustable, ensuring consistent post‑processing performance.
Powder2Powder (P2P) technology integrates two core processes—plasma treatment and ultrasonic atomization—enabling the efficient conversion of raw powder with irregular morphology, oversized particle sizes, or degraded performance into high‑quality spherical powder that exhibits excellent sphericity, no satellite particles, and superior flowability, thereby enhancing both the build stability and part quality in additive manufacturing (AM).
During the process, raw powder is precisely delivered into the molten pool via a plasma torch, achieving complete remelting and compositional homogenization, thereby eliminating inherent particle defects and compositional inhomogeneities at their source. Subsequently, ultrasonic atomization is employed; leveraging the stable standing waves generated within the molten pool, the molten metal is accurately sprayed and shaped into next-generation high-performance powders.
Compared with conventional plasma spheroidization techniques, P2P technology is not constrained by the particle size of the feedstock. Moreover, this system can directly process mixtures of powders from multiple elements, enabling in-situ preparation of pre-alloyed powders with precise compositions and uniform microstructures, thereby offering a material‑production and recycling‑reclamation solution for high‑end additive manufacturing.
Advantages and Features
With this cutting-edge, integrated solution, end-to-end management of metal powder production becomes efficient, convenient, and fully controllable. The equipment enables continuous closed-loop manufacturing, unaffected by fluctuations in the quality of raw powder, ensuring that each batch consistently delivers high‑sphericity, high‑performance, premium metal powders—thereby guaranteeing stability from the very outset for additive manufacturing and materials R&D.
- From a cost and operational standpoint, the solution can substantially reduce powder procurement costs and streamline the purchasing process: by acquiring raw powder in a single purchase, it enables repeated reuse through cyclical regeneration until complete consumption, thereby significantly cutting down on redundant procurement and capital tied up in inventory, and comprehensively enhancing production and operational efficiency.
- In terms of environmental protection and sustainability, the system significantly reduces powder waste and disposal burdens by replacing direct disposal with recycling and reuse, minimizing resource consumption and environmental impact. It establishes a green, sustainable closed-loop production chain, deeply integrating powder recovery, regeneration, and reuse into every stage of the manufacturing process, thereby achieving a win-win outcome for both economic and environmental benefits.
- The solution also boasts exceptional flexibility: it can directly leverage a company’s existing waste materials and idle powders to customize new materials, blend and recycle powders from different batches and compositions, and produce novel alloy powders with uniform particle size and precise compositional control, thereby meeting customized requirements.
As a versatile research platform for metallic materials, a single piece of equipment can accommodate multiple feedstocks to produce high‑quality metal powders, while also featuring an efficient atomization capability that provides robust support for materials development. With this system, research teams can leverage recycled materials to pioneer entirely new avenues of inquiry and explore a broader range of innovative application scenarios.
Equipment Parameters
| Core Features | Metal powder regeneration and processing combined with performance modification; each module can operate independently or in coordinated mode. |
| Handling powder types | Mainstream metal powders for additive manufacturing, including iron-based, titanium-based, aluminum-based, and nickel-based powders. |
| Handling in powder form | Additive manufacturing waste powder, residual powder, and newly produced powder |
| Process stage | Pretreatment, purification and impurity removal, thermal regeneration, performance modification, and graded collection |
| Atmosphere control | A fully argon/nitrogen protective atmosphere is maintained throughout the process, with pressure adjustable within the range of 0.2–0.6 MPa. |
| Heating temperature | Purification and impurity removal module: ≤600°C; hot‑state regeneration module: ≤800°C; modification module: ≤1000°C; temperature accuracy: ±3°C. |
| Particle size processing range of the powder | 20–150 μm, enabling graded collection within a specific particle size range. |
| Device Specifications | Compact laboratory design, with a footprint of ≤2.2 m² and an overall weight of ≤500 kg. |
| Operating method | Touchscreen operation, supporting both independent and linked control of process parameters. |
| Feeding method | Quantitative powder feeding, with a single‑batch feed rate of ≤1 kg, suitable for small‑scale laboratory processing. |
| Impurity removal method | Magnetic separation + air‑flow classification + vacuum high‑temperature purging, with a impurity removal efficiency of ≥95%. |
| Modified functionality | Particle size optimization, surface modification, and compositional fine-tuning can be implemented individually or in combination. |
| Powder Collection | Multi-stage airflow classification and collection, with a collection efficiency of ≥85%, and customizable particle size ranges. |
| Process Storage | Supports storage of ≥100 sets of process parameters, including regeneration and modification processes for different powders. |
| Cooling system | Closed-loop cooling, tailored to meet the cooling requirements of each module. |
Download Materials
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
In recent years, as global demand for clean energy has surged, high‑efficiency energy storage technologies have become a major research focus in the energy sector. Among these, latent heat thermal energy storage (LHTES) has attracted considerable attention due to its high energy density and excellent stability. Recently, a joint team comprising researchers from the Norwegian University of Science and Technology and Poland’s Warsaw University of Technology, among other institutions, published a groundbreaking study in the journal Results in Engineering: they have, for the first time, successfully developed microcapsules containing an ultra‑high‑temperature phase change material (PCM) based on a silicon–iron eutectic alloy. This material can operate at temperatures exceeding 1,200°C, with an energy storage density far surpassing that of existing technologies. In this article, we will explore this cutting‑edge advancement, covering its background, underlying technical principles, experimental results, and potential future applications.
With the rapid advancement of 3D printing (additive manufacturing) technology, demand for high-performance metal powders continues to grow, particularly in sectors such as aerospace, automotive, and medical industries. As a next-generation metal powder, titanium-based composite powders have become a research hotspot due to their excellent properties, including light weight, high strength, and corrosion resistance. However, conventional powder‑making methods suffer from issues like uneven particle size, severe agglomeration, and compositional heterogeneity, which limit their practical applications. Recently, an innovative ultrasonic atomization technique has offered a new solution to these challenges. This paper provides an in-depth exploration of “Preparation and Performance Study of Multi‑Scale Enhanced Titanium‑Based Composite Powders via Ultrasonic Atomization,” proposed by Professor Dong Fuyu of Shenyang University of Technology and his colleagues. It examines the process flow, microstructure, mechanical and functional properties, and potential future applications of this advanced material.
In the aerospace sector, nickel-based superalloys have long been the material of choice for manufacturing critical engine components, thanks to their outstanding high-temperature performance. With the advancement of additive manufacturing technologies, the demand for high-quality nickel-based superalloy powders has grown increasingly urgent. However, conventional powder‑making methods either fail to meet quality standards or suffer from low efficiency, posing significant challenges to the industry. Fortunately, a new approach—Self‑Impact Ultrasonic Atomization (SIUA)—developed by a team at Dalian University of Technology has successfully overcome these limitations, opening up a promising new pathway for producing nickel‑based superalloy powders.
This paper presents a recent research achievement: powder production using the rePowder ultrasonic atomization system from AMAZEMET. Through systematic design and microstructural control, an innovative aluminum alloy has been successfully developed, exhibiting high strength, excellent ductility, and superior high-temperature resistance, thereby opening up new prospects for enhancing the performance of aluminum alloys in additive manufacturing.
With the continuous advancement of materials science, the demand for high-performance alloys with superior corrosion resistance and wear resistance is steadily increasing. Particularly in industries such as aerospace, energy, and electronics, the performance requirements for coating materials are constantly rising. Traditional preparation methods—such as powder metallurgy and mechanical milling—are increasingly unable to meet the needs for precise control and functionalization of complex materials. Against this backdrop, ultrasonic atomization, a green and highly efficient powder‑production technology, has emerged as a cutting‑edge approach and is rapidly becoming a focal point in the research and development of advanced materials.
Atomization Process of Indium Alloy
Ultrasonic Atomization Induction Melting
Atomization Powder Production Using Aluminum Alloy Vibration Sheets
Ultrasonic Atomization Induction Melting of Metallic Glasses
Iridium ultrasonic atomization focused plasma
Ultrasonic Atomization Arc Plasma Melting
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