AMAZEMET, a Warsaw-based company developing ultrasonic atomization systems and laboratory-scale equipment for additive manufacturing, has introduced a new on-demand atomization service aimed at researchers working on experimental metal powders. The Atomization Service enables small-batch production starting at just 50 grams of material, addressing a persistent bottleneck in materials research and alloy development.
Conventional techniques such as gas or plasma atomization are optimized for industrial-scale output and typically require feedstock quantities in the tens of kilograms. This makes them economically impractical for developing small quantities of novel alloys. The new offering relies on ultrasonic atomization, a process that converts up to 80% of the input into spherical powder within the 15 to 63 micron range. According to CEO Dr Łukasz Żrodowski, the goal is to reduce barriers to innovation: “Researchers with brilliant ideas were being held back by prohibitive costs and the inability to procure small, experimental batches of high-quality spherical powders. Our new service directly removes that barrier, enabling faster discovery and development.”
To ensure precise chemical compositions, the process includes pre-treatment using in-house arc melting and homogenization. It is capable of handling high-temperature and reactive elements such as titanium, magnesium, gadolinium, and refractory metals. Powder2Powder technology supports re-atomization of used or off-spec powders, as well as direct processing of broken samples and mechanical test remnants. Multi-material orders are accepted within a single job, allowing labs to explore several compositions without additional setup costs.
Processing parameters are shared with clients to support reproducibility. Guidance is also provided by the company’s team of researchers, including PhDs and PhD candidates in materials science. This new service builds on the firm’s existing infrastructure, which includes compact vacuum furnaces for post-processing and ultrasonic atomization hardware developed for small-scale additive workflows.
AMAZEMET was founded to address critical gaps in research infrastructure for metal 3D printing. Its new atomization offering aligns with growing demand for customized powders with controlled particle morphology, low oxygen content, and narrow size distribution—essential requirements for powder bed fusion and other additive processes. Researchers can request custom powders by contacting the company’s application team or submitting specifications through the order form on AMAZEMET’s website.
Atomization and Alloy Powder Qualification in Aerospace
Velo3D, a U.S.-based metal 3D printer manufacturer, is advancing qualification of Amaero Ltd’s C103 niobium and Ti-6Al-4V titanium powders, following successful testing by Auburn University’s National Center for Additive Manufacturing Excellence (NCAME). Amaero, a producer of specialty alloy powders, uses advanced atomization technology to manufacture these materials. C103 passed ASTM F3635 Class B standards after a 2200°F heat treatment, while the Ti-6Al-4V powder met AMS7015 and ASTM F3001 specifications. Velo3D will now proceed with in-house validation and print testing using its Sapphire systems, and over 1,000 kg of powder are scheduled for delivery in Q3 2025 to support aerospace and defense projects.
Separately, Canadian company PyroGenesis has confirmed Boeing as the aerospace partner in its Ti64 metal powder qualification process. The company’s coarse-grade titanium powder, produced with its NexGen plasma atomization system, has met Boeing’s technical standards and is undergoing final steps toward supplier approval. The powder, with a particle size range of 45 to 150 microns, is designed for use in Electron Beam Melting (EBM) and Direct Energy Deposition (DED) processes. PyroGenesis has stockpiled Ti64 powder in preparation for project deployment, pending completion of Boeing’s approval procedures in early 2025.
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Featured photo shows ultrasonic atomization with Plasma (left) and Induction Melting (right) using rePOWDER. Photo via AMAZEMET.
