Powder2Powder
Achieve powder recycling and significantly enhance powder utilization in additive manufacturing.
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 for continuous powder handling
Compatible with a wide range of mainstream additive manufacturing powders, with highly targeted performance.
Flexible operating modes 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:
Are you still struggling with unusable metal powders? The handling of nonconforming metal powders presents a host of practical challenges: process-generated, non-recyclable powder leads to cost waste and necessitates continuous procurement of new powder; idle powder occupies valuable storage space and is subject to stringent safety requirements for storage and handling; in additive manufacturing, the use of mixed powders can compromise the quality of the final printed parts; moreover, nonconforming powders are subject to regulatory and environmental compliance restrictions, prohibiting their indiscriminate disposal, which results in complex and costly disposal procedures; in addition, inspecting and managing residual powder is time-consuming, and if inspection results fail to meet specifications, re-purchasing and re-testing are required, further delaying production. Currently, the metal powder industry faces significant challenges in powder recovery and reuse, underscoring the urgent market need for innovative solutions.
Currently, no perfect solution is available on the market for metal powder recycling that is well-suited to small- and medium-scale operations; existing technologies all have limitations:
- Plasma spheroidization uses a plasma jet to remelt powder particles into spherical shapes, thereby improving flowability, optimizing particle-size distribution, and eliminating internal defects; however, it cannot alter particle size or achieve uniform mixing of powders.
- Screening and classification can separate acceptable powder from nonconforming powder based on particle size and optimize the particle-size distribution, but they cannot improve flowability or remedy powder defects.
- Reatomization involves remelting and reatomizing degraded powder to produce qualified powder with uniform properties, making it an effective method for repairing powders with abnormal morphology. However, it is costly, energy-intensive, and requires sophisticated equipment, rendering it economically unviable for small- and medium-scale recovery operations. Moreover, repeated remelting can lead to fluctuations in alloy composition and oxidation, thereby degrading 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 performance modification of metal powders. Focusing on the needs of powder recycling and performance optimization in the field of metal additive manufacturing, it provides a dedicated solution for the “recycling–regeneration–modification” of metal powders. Leveraging the brand’s extensive technological expertise in ultrasonic atomization and materials processing, Powder2Powder offers robust hardware support for both powder recycling and performance enhancement. Unlike conventional powder-processing equipment that typically addresses only a single stage of the process, Powder2Powder can recover and regenerate waste and residual powders generated during metal additive manufacturing, while also enabling performance modification and optimization of regenerated or newly produced powders. This significantly 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 that is well-suited to research institutions and additive-manufacturing companies’ labs and small-batch production settings. It can handle a wide range of commonly used metal powders for additive manufacturing, including iron-based, titanium-based, aluminum-based, and nickel-based powders, and tailors proprietary 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 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 to meet specific requirements, bringing the performance of regenerated powders up to or even close to the standards of new powders—and in some cases, further enhancing the performance of modified powders through tailored treatments. Powder2Powder has been adopted by numerous additive-manufacturing firms and research institutions worldwide, helping to realize the circular use of metal powders. In practical applications, it can raise the powder utilization rate in metal additive manufacturing to significantly higher levels. Moreover, the system is easy to operate, with controllable process parameters that can be flexibly adjusted according to the degree of powder contamination and specific performance requirements, thereby providing technical support for the green development of metal additive manufacturing. It stands as AMAZEMET’s flagship equipment for advancing material recycling.
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 pretreatment, purification and impurity removal, thermal regeneration, performance modification, and graded collection of the finished product. Each stage is implemented through dedicated process modules to enable continuous operation, and all processes are carried out under a controlled protective atmosphere to prevent secondary oxidation and contamination during treatment. First, the waste powder, residual powder, or newly produced powder to be processed is fed into the equipment via a metering feed module and then enters the pretreatment sub-module. Here, low-speed stirring combined with air-flow dispersion breaks up particle agglomerates, resulting in a uniformly dispersed powder state. Simultaneously, magnetic separation removes ferromagnetic impurities, completing the initial pretreatment. The stirring speed and air-flow dispersion intensity in this stage can be adjusted according to the initial condition of the powder, allowing for optimal adaptation to powders with varying degrees of agglomeration. Subsequently, the pretreated powder proceeds to the purification and impurity-removal module, which employs a combination of air-classification and vacuum purging. By precisely controlling the air-flow velocity, fine-particle impurities, large agglomerates, and qualified powder are initially separated. At the same time, under vacuum conditions, the powder undergoes high-temperature purging to remove surface oxide layers and adsorbed impurity gases. The temperature and duration of the high-temperature purging can be tailored to the material properties of the powder, ensuring that the oxide layer is effectively removed without altering the powder’s original microstructure. Next, the purified powder enters the thermal-regeneration module, where it undergoes low-temperature hot sintering under a protective atmosphere. Through precise control of temperature and holding time, surface micro-defects generated during additive manufacturing are repaired, while the sphericity of the powder is slightly optimized, restoring its flowability and powder-bed spreading characteristics. The heating temperature in this stage is significantly lower than the powder’s melting point, thereby preventing melt-induced agglomeration and preserving the powder’s original particle-size distribution. If performance modification is required, the regenerated powder then moves to the performance-modification module, which offers three core modification functions as needed: particle-size optimization via precise air-classification; surface repair through vapor-phase deposition to achieve micro-coating of the powder surface and rectify surface defects; and compositional fine-tuning via precise powder blending to ensure uniform doping of trace elements, thereby optimizing the powder’s composition and performance. Finally, the regenerated or modified powder enters the graded-collection module, where multi-stage air-classification enables precise separation and collection of powders across different particle-size ranges. Depending on the requirements of the additive-manufacturing process, finished powders within specific particle-size ranges can be collected. The entire processing sequence is continuous and stable, with all process parameters independently and precisely controllable, thus ensuring consistent post-processing performance of the powder.
Powder2Powder (P2P) innovative technology seamlessly 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 powders that exhibit exceptional sphericity, zero satellite particles, and outstanding flowability. This significantly enhances 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 fundamentally eliminating pre-existing particle defects and compositional inhomogeneities. Subsequently, ultrasonic atomization is employed: leveraging the stable standing waves generated within the molten pool, the molten metal is accurately sprayed and formed into a new generation of high-performance powders.
Compared with conventional plasma spheroidization technologies, P2P technology is not constrained by the particle size of the feedstock and is one of the few proprietary processes worldwide capable of directly atomizing titanium powder. Moreover, this system can directly process mixtures of powders from multiple elements, enabling in-situ preparation of pre-alloyed powders with precise compositional control and uniform microstructure, thereby providing an unprecedented materials-processing and recycling 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 that is unaffected by fluctuations in the quality of raw powder, ensuring consistent output of high-sphericity, high-performance metal powders batch after batch—thereby guaranteeing the stability of additive manufacturing and materials R&D from the very source.
- From a cost and operational perspective, this solution can substantially reduce powder procurement costs and streamline the procurement process: by making a single purchase of raw powder, it can be repeatedly reused through recycling and regeneration until fully consumed, thereby significantly reducing the need for repeated purchases 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, thereby minimizing resource waste and environmental impact. It establishes a green, sustainable closed-loop production chain that deeply integrates powder recovery, regeneration, and reuse into every stage of the manufacturing process, 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, blending and reprocessing powders from different batches and with varying compositions to produce novel alloy powders that are uniformly granulated and precisely composited, thereby meeting customized requirements.
As a multifunctional research platform for metallic materials, this single piece of equipment is compatible with a wide range of feedstocks to produce high-quality metal powders, while also featuring highly efficient atomization capabilities that provide robust support for materials development. With this system, research teams can leverage recycled materials to pioneer entirely new research directions, explore a broader array of innovative application scenarios, and elevate both materials R&D and process innovation to unprecedented levels.
Equipment Parameters
| Core Features | Metal powder recycling and 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 powder form | Additive manufacturing waste powder, residual powder, and newly produced powder |
| Process stage | Pre-treatment, purification and impurity removal, thermal regeneration, performance modification, and graded collection |
| Atmosphere control | Continuous argon/nitrogen protective atmosphere, with adjustable pressure ranging from 0.2 to 0.6 MPa. |
| Heating temperature | Purification and impurity removal module: ≤600°C; thermal regeneration module: ≤800°C; modification module: ≤1000°C; temperature accuracy: ±3°C. |
| Particle Size Range for Powder | 20–150 μm, enabling graded collection within a specified particle size range. |
| Equipment Specifications | Compact laboratory design, with a footprint of ≤2.2㎡ and a total weight of ≤500kg. |
| Operation method | Touchscreen operation, supporting both independent and linked control of process parameters. |
| Feed method | Quantitative powder feeding, with a single feed dose ≤ 1 kg, suitable for small-batch laboratory processing. |
| Impurity removal method | Magnetic separation + air-classification + vacuum high-temperature purging, with impurity removal efficiency ≥95%. |
| Modified function | Particle size optimization, surface repair, and compositional fine-tuning can be performed individually or in combination. |
| Powder Collection | Multi-stage airflow classification and collection, with a collection efficiency of ≥85%, and customizable particle size range. |
| 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 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, driven by the surging global demand for clean energy, high-efficiency energy-storage technologies have emerged as a research hotspot in the energy sector. Among these, latent-heat thermal energy storage (LHTES) has garnered significant attention due to its high energy density and excellent thermal stability. Recently, a joint team from the Norwegian University of Science and Technology and Warsaw University of Technology in Poland, among other institutions, published a groundbreaking study in the journal Results in Engineering: for the first time, they have successfully developed ultra-high-temperature phase-change material (PCM) microcapsules based on a silicon–iron eutectic alloy, with an operating temperature exceeding 1,200°C and an energy-storage density far surpassing that of existing technologies. This article will provide an overview of 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, the demand for high-performance metal powders is steadily increasing, particularly in industries such as aerospace, automotive, and medical. As a next-generation metal powder, titanium-based composite powder has emerged as a research hotspot due to its outstanding properties, including low density, high strength, and excellent corrosion resistance. However, conventional powder-production methods suffer from issues such as non-uniform 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 the “Preparation and Performance Study of Multi-Scale Reinforced Titanium-Based Composite Powders via Ultrasonic Atomization,” proposed by Professor Dong Fuyu and his team at Shenyang University of Technology. It examines the process flow, microstructure, mechanical and functional performance, and future application prospects of this material.
In the aerospace sector, nickel-based superalloys have long been the material of choice for manufacturing critical engine components due to their outstanding high-temperature performance. With the rapid advancement of additive manufacturing technologies, the demand for high-quality nickel-based superalloy powders has grown increasingly urgent. However, conventional powder-production methods either fail to meet quality standards or suffer from low efficiency, posing significant challenges to the industry. Fortunately, a recent breakthrough by a team at Dalian University of Technology—the Self-Impact Ultrasonic Atomization (SIUA) method—has successfully overcome these bottlenecks, opening up a new avenue for the production of nickel-based superalloy powders.
This paper presents a recent research achievement: the preparation of powders using AMAZEMET’s rePowder ultrasonic atomization system. Through systematic design and microstructure control, an innovative aluminum alloy with high strength, high ductility, and excellent high-temperature resistance has been successfully developed, opening up new prospects for enhancing the performance of 3D-printed aluminum alloys.
With the continuous advancement of materials science, the demand for high-performance alloys with superior corrosion resistance and wear resistance is steadily increasing. This is particularly true in industries such as aerospace, energy, and electronics, where the performance requirements for coating materials are constantly rising. Traditional powder-production methods, including powder metallurgy and mechanical milling, are increasingly unable to meet the need for precise control and functionalization of complex materials. Against this backdrop, ultrasonic atomization—a green and highly efficient new powder-production technology—has gradually emerged as 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
Beijing Yunshang Intelligent Manufacturing Technology Co., Ltd.
Hotline(24 hours a day)
Headquarters Address: Room 708, Building 2, HICOOL Industrial Park, Nanfaxin, Shunyi District, Beijing
Follow
Customer service WeChat
WeChat Official Account
COPYRIGHT 2026 Beijing Yunshang Intelligent Manufacturing Technology Co., Ltd.
Powered by 300.cn Privacy Policy
YUNS-123456
Smart Customer Service
WhatsApp：864009005667
Company email：support@chinayuns.com
Telephone：400 900 5667