Success Stories – Dev

Aerospace optimization and manufacturing process improvement using ceramic 3D printing

VS — Wed, 12 Oct 2022 09:03:07 +0000

Aerospace optimization and manufacturing process improvement using ceramic 3D printing

The aim

The aerospace industry is constantly seeking to optimize the performance of its equipment (satellites, measurement tools, optical instrumentation, etc.) by exploiting the properties of ceramic materials. Of importance is the quick turnaround between design of components and delivery of these components. Ceramic 3D manufacturing offers an unique solution to the aerospace industry. You will be able to quickly design and manufacture complex and unique parts without large scale investments.

Advantage of technology

The ceramic materials used in 3D printing are very resistant and have exceptional physicochemical properties (eg. corrosion resistance, electrical insulation).
Ceramic products suffer too often from the limit of traditional means of manufacture, limiting their uses to massive parts and little stress. However, with 3DCeram printers, you have all the freedom degrees for the production of complex ceramic materials for the aerospace industry.

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SLA printing reduced the production cycle of an aircraft engine sleeve by 3 months

VS — Sat, 18 Mar 2023 09:05:30 +0000

SLA printing reduced the production cycle of an aircraft engine sleeve by 3 months

The aim

To reduce the production time for a passenger aircraft part.

The solution

SLA printing with QuickCast technology has reduced the production time for bushing used in aircraft engines. The technology creates a solid shell of the model and is filled with a cellular structure, which increases the burnout process several times. It leaves no ashes, and the final part shape remains the same as the original 3D model.

The use of QuickCast 3D printing technology enables saving materials while producing the most detailed part with a high resolution. After assembling all parts, it was covered with a special ceramic composition, and the metal was poured into the mold. After solidification and removal of the form, the final part was taken out.

Conclusion

The Quick Cast model replaces traditional casting models and does not require expensive tooling. Thus, the company reduced the cost of casting models by 95%.
SLA printing reduced the production cycle by 3 months. Nexa3D printer solves a number of aerospace production tasks, as well as 3DCeram equipment, which produces ceramic parts for complex circuits.

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CAD to Part in 48 Hours: PepsiCo Slashes Tooling Costs and Cycle Times with the help of NXE 400

Ashkhen — Tue, 26 Mar 2024 15:55:24 +0000

Iconic PepsiCo Brand Finds Best Alternative to Expensive, Time-Consuming Conventional Metal Tooling

PepsiCo products are enjoyed by consumers more than one billion times a day in more than 200 countries and territories around the world. PepsiCo generated more than $79 billion in net revenue in 2021, driven by a complementary beverage and convenient foods portfolio that includes Lay’s, Doritos, Cheetos, Gatorade, Pepsi-Cola, Mountain Dew, Quaker, and SodaStream. PepsiCo’s product portfolio includes a wide range of enjoyable foods and beverages, including many iconic brands that generate more than $1 billion each in estimated annual retail sales.

The Challenge

Speed to market is crucial in the consumer goods industry, where companies are constantly striving to create new bottle and package designs that cater to changing customer preferences. However, the traditional method of making metal tooling for blow molding bottles is both costly and time-consuming. After designing a package using CAD software, it can take up to four weeks to manufacture a metal tool, followed by an additional two weeks to test the blow molding process. According to Max Rodriguez, a senior manager at PepsiCo’s Valhalla research center, the production of a single metal tool set can cost up to $10,000 depending on its complexity.

In an effort to expedite this process, many have turned to 3D printing, but previous attempts at rapid tooling had their limitations. Printing a blow molding tool from Digital ABS material on a PolyJet 3D printer costing $250,000 would take two to three days, but the resulting tool lacked durability and could only produce around 100 bottles before failing. To address these challenges, Rodriguez and his team are now exploring a hybrid approach that combines elements of a traditional metal mold with 3D printed inserts.

Company

PepsiCo Inc.

Industry

Consumer goods packaging, food & beverage

Printer

Nexa3D NXE 400 Printer

Material

xPEEK147 by Henkel Loctite

Application

Applying its patented technology and a hybrid approach, PepsiCo is using additive manufacturing as an enabler in various aspects of bottle development – accelerating and enhancing performance simulation, advanced system analysis and the production of high-quality, functional prototypes.

Advantages

Compress prototype tooling development time from 4 weeks to 48 hours
Slash prototype tooling costs from $10,000 to $350 per mold set
Create durable tooling that can produce more than 10,000 bottles per mold
Enable multiple design iterations to allow for timely verification of downstream activities

More Than 10,000 Bottles at 96% Reduction in Cost

PepsiCo went with Nexa3D’s xPEEK147 from Henkel Loctite for the 3D printed tool inserts because of its strength and impressive performance features, like its high heat-deflection temperature. This hybrid approach can work with different types of 3D printers, but PepsiCo has found that the super-fast, high-capacity Nexa3D NXE 400 3D printer and its materials are perfect for making the mold parts they need.

A full set of molds can be produced in just 12 hours, with 8 hours of printing and 4 hours of curing. These hybrid molds can then be used for over 10,000 bottles before needing replacement – all at a cost reduction of up to 96% compared to traditional metal tooling.

Explore What’s New in 3D Printing

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Parts in the New Apple Watch Ultra to Reportedly be 3D Printed

Ashkhen — Mon, 20 May 2024 13:34:07 +0000

The next version of the Apple Watch Ultra will feature some mechanical titanium parts produced using additive manufacturing (AM)

According to a Medium post by financial analyst Ming-Chi Kuo, who covers Apple for Hong Kong investment bank TF International, the next version of the Apple Watch Ultra will feature some mechanical titanium parts produced using additive manufacturing (AM). Kuo expects the second-generation Apple Watch Ultra to launch sometime before the end of 2023, following the product’s initial release in September, 2022.

Kuo typically gets his data, including the intel regarding the 3D printed parts, from “his contacts in Apple’s Asian supply chain”, according to the online publication MacRumors. That website also notes that Kuo’s “[predictions] are accurate enough to make him one of the most reliable sources for Apple rumors.” Kuo named three companies that will be used by the world’s largest corporation in its AM operations for Apple Watch Ultra parts: IPG Photonics is supplying the laser components, while Chinese original equipment manufacturers (OEMs) Farsoon and Xi’an Bright Laser Technologies (BLT) are providing the platforms.

The fact that Apple is using Chinese platforms, in particular, is especially interesting, given that the company has been perhaps the most oft-cited corporation in the last couple of years as an example of Western companies diversifying their manufacturing operations out of mainland China. The use of Chinese AM platforms in this case would highlight something I’ve mentioned frequently in the past few months, in the context of “de-risking” related to China: the emergence of distributed supply chains could allow the world’s largest manufacturers to limit the growth of physical economic connections by substituting them with digital connectivity.

While the use of Chinese hardware would still of course require shipment of printers, Farsoon and BLT already have customers around the planet, with Farsoon having both American and European offices in addition to its Hunan headquarters. BLT, moreover, just recently signed a deal to sell its products in Japan, which could similarly fit the concept of spreading out the manufacturing footprint of Western companies more evenly across Southeast Asia.

In any case, shipping printers should, in the long run, lead to much less global traffic than perpetuating the supply chains necessary to ship millions of tiny consumer goods across opposite ends of the planet. As Kuo writes in his Medium post, “If shipments go well, I believe more Apple products will adopt 3D printing technology, which will help improve production cost and ESG performance in Apple’s supply chain…”

Things could start to turn heavily in that direction very quickly, as, less than a month ago, Apple held its first “Smart Manufacturing Forum” for small and medium enterprises in South Korea. In addition to South Korea, India could also eventually be a major beneficiary of any 3D printing-driven smart manufacturing strategy. Apple is eager to ramp up its India operations, even amid news last week that Foxconn — the main manufacturer of Apple products — had pulled out of a nearly $20 billion semiconductor factory in Gujarat. Despite that, Foxconn is still planning on going forward with other new factory sites in India.

Above all, I think this sends a clear signal that diversification out of China is much more about supply chain flexibility than it is about imperialistic grandstanding. It is by no means a cut-and-dry issue with a one-size fits all solution that can be ushered in sweepingly, but a generational project that will require myriad approaches tailored to individual cases: a project which can only be built up bit by bit by precisely the interests responsible for supergluing the US and China together in the first place.

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Farsoon SRS (Support Free) Technology: reduce support up to 99.8%

Ashkhen — Thu, 01 Aug 2024 09:34:50 +0000

Farsoon Technology has successfully achieved support-free technology for special structures such as horizontal circular holes and inverted cones.

Support-free technology allows the production of complex geometries without the need for additional support structures. This innovation is particularly beneficial for creating intricate designs, such as horizontal circular holes and inverted cones, which are often challenging to manufacture using traditional methods.

Support-free technology not only reduces material waste but also minimizes post-processing time and costs associated with removing supports. This capability enhances design freedom, enabling engineers and designers to explore more innovative solutions and optimize parts for performance and weight reduction.

Advances in Suspended Structures and Support-Free Printing

The smooth formation of parts is a fundamental requirement in additive manufacturing. However, the rapid cooling rates associated with metal powder bed fusion technology can create significant internal stresses during the forming process, leading to deformation of the parts. This issue is particularly pronounced in suspended structures, where warping can result in printing failures—an ongoing challenge for designers.

Thanks to relentless innovation and independent research and development, Farsoon Hi-Tech, a leader in industrial 3D printing, has tackled these technical hurdles head-on. They’ve successfully mastered the creation of complex structures like inverted cones and horizontal circular holes. Notably, they can achieve an infinite height for inverted cone structures with angles between 20° and 25°. Additionally, they can form horizontal circular holes up to 50mm in diameter without the need for support.

Metal additive manufacturing faces support design challenges

A well-thought-out structural design and the right forming process are crucial for achieving smooth part production. In metal additive manufacturing, creating suspended structures often requires additional support, particularly in areas with a low-hanging angle. Typically, support structures are added to any suspended sections that have an inclination of less than 45 degrees to minimize the risk of failure during the printing process.

However, using supports comes with its own set of challenges. For starters, adding supports means consuming extra powder material, which not only prolongs printing time but also complicates post-processing efforts. Some supports can be difficult or even impossible to remove without damaging the final part, rendering it unusable.

To tackle these issues, designers must carefully consider the unique characteristics of additive manufacturing and make structural adjustments to reduce the need for supports while ensuring they remain removable. This can impose additional constraints on the design process.

Given these challenges, it’s essential to refine the forming process and improve the capability of materials and techniques for low-angle formations. Enhancing these aspects can significantly streamline production and lead to better outcomes in metal additive manufacturing.

Special structure to achieve no support

Farsoon understands that the forming capability in additive manufacturing is heavily influenced by factors like material choice, layer thickness, and process parameters. Interestingly, even structural parts with the same inclination angle can present varying degrees of forming difficulty. For instance, creating an inverted cone is generally more challenging than forming a right hollow cone, despite their identical angles.

This highlights the importance for material and process developers to establish clear verification standards for forming capabilities. Farsoon has dedicated significant resources to forward-thinking research and development aimed at optimizing material forming processes. With years of technical expertise and innovative breakthroughs under their belt, they’ve developed proprietary slicing software that employs adaptive intelligent scanning strategies. This allows for precise control over energy input and localized heating during production. As a result, Farsoon has significantly enhanced forming capabilities while maintaining part density, outperforming traditional scanning technologies.

At Farsoon High-Tech, the team is committed to continuous innovation and independent research and development. They have successfully addressed the technical challenges associated with forming complex structures, such as inverted cones and horizontal circular holes. Their latest breakthrough enables the infinite height forming of inverted cone structures with inclination angles ranging from 20° to 25°. Additionally, they can create horizontal circular holes up to 50mm in diameter without the need for support.

Farsoon’s process optimization not only reduces the number of supports required for these intricate parts but also enhances design flexibility. This advancement allows clients to push the boundaries of their workpiece designs while simplifying post-processing requirements. With Farsoon, customers are not just accessing advanced technology; they are gaining the freedom to innovate.

More than 10 applications have been mass-produced

The low-support technology has been applied to dozens of workpieces and achieved mass production. The materials include titanium alloy, high-temperature alloy, aluminum alloy, stainless steel, etc. Typical applications include fuel tanks, closed impellers, valve bodies, nozzles and other parts, and the maximum size of the workpiece exceeds 450mm.

Three major advantages of low support/no support technology

Cut production and post-processing time while slashing costs. For instance, when producing an IN718 closed impeller with a diameter of about 130mm and a height of around 50mm, you can reduce printing time by 33% and lower costs by over 25%. Parts that require more supports can see even greater savings in both time and expenses.

Enhance your product quality by minimizing metallurgical defects that often arise at the junction where supports meet the workpiece. When you remove those supports, the workpiece itself can be vulnerable to damage. Plus, any debris left behind can easily infiltrate narrow structures like flow channels, leading to unwanted material buildup. By cutting down on the amount of support needed, you can significantly mitigate these issues and boost the overall integrity of your parts.

Unlock new design possibilities! Say goodbye to the old 45° forming angle constraint and expand your creative horizons. Take small parts with intricate inner cavity structures, for instance. Traditional printing methods often force you to tweak your designs or pile on excessive support, which can lead to local deformations in those delicate areas. By embracing a support-free strategy, you can achieve smooth, flawless formations without compromising your design integrity. Let your creativity flow!

Metal additive manufacturing technology still has great potential to be tapped

Farsoon will continue to conduct in-depth research and exploration of the potential of metal additive manufacturing technology and innovative processes to further unleash its innovative vitality and development space.

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Inspection and Quality Control of Carbon Fiber Monocoque for Hypercars with FreeScan Trak Pro2

Ashkhen — Mon, 30 Jun 2025 12:06:52 +0000

Hypercars represent the pinnacle of automotive engineering, where precision, quality, and zero compromises define every component. To meet these high standards, Bugatti-Rimac has integrated SHINING 3D’s FreeScan Trak Pro2 into its state-of-the-art metrology lab, ensuring flawless accuracy in its quality control process.

Bugatti-Rimac: A Fusion of Automotive Excellence

Bugatti-Rimac is a strategic joint venture between two legendary automotive brands: Bugatti Automobiles, which has over 110 years of heritage, and Rimac Automobili, renowned for its leadership in high-performance electric vehicles (EVs). Under the leadership of Mate Rimac, the company is headquartered in Sveta Nedelja and plans to transition into the €200M Rimac Campus—a next-generation facility for hypercar manufacturing and advanced EV technology development.

Rimac Automobili: Nevera

At the heart of Rimac Automobili’s production is Nevera, a groundbreaking electric hypercar with record-breaking performance. Its carbon fiber monocoque—the largest ever used in series production—is subjected to rigorous quality control to ensure each unit meets specifications. Exact measurements guarantee perfect fitting between it and any mounted elements like suspension, etc. The 200 kg structural and engineering masterpiece that serves as the backbone of the vehicle is the biggest piece that needs to be validated before production begins.

“At Rimac, precision is everything. Every component must meet the highest standards to ensure performance and safety.”
— Annamaria Hamata, Quality Analyst

Nevera’s Carbon Fibre Monocoque

Inspection of High-End Hypercars Requires High-End 3D Digitizing Solutions

Bugatti-Rimac employs a combination of inspection procedures, including 3D scanning, to guarantee flawless quality in production. After first integrating the FreeScan Trak Pro in 2023, the company upgraded to the FreeScan Trak Pro2, boosting efficiency and precision in their metrology-driven workflow.

Ivan Radicevic (quality control technician of Bugatti-Rimac) is using FreeScan Trak Pro2 for monocoque scanning

Metrology for quality control

Handheld FreeScan Trak Pro2 3D Scanner

The FreeScan Trak Pro2 is a 3D handheld scanner offering markerless optical 3D measurement with dynamic tracking for large workpieces....
Read more

3D Scanning Operation of Nevera Monocoque in the Metrology Lab

With high precision and repeatability, the FreeScan Trak Pro2 allows for fast, accurate inspection of various part types and surfaces without the need for markers. It is the ideal metrology tool for quality control and 3D inspection.

No Markers Needed
Exceptional Accuracy
Wide Measuring Range
Accuracy of 0.023 mm (0.0009 in)
High-speed scanning up to 3,070,000 points/s
Large tracking range
Compatible with FreeProbe (optional)

3D Scanning Operation of Nevera Monocoque in the Metrology Lab

One of the most critical elements inspected is Nevera’s carbon fiber monocoque, which is the main chassis part and the literal backbone of the entire vehicle. The goal is to validate the monocoque’s production quality, align it with other carbon fiber components, and ensure the precise positioning of mounting points for the suspension, drivetrain, and chassis elements.

In this case, mounting points on the chassis, the underside, and key cockpit features were scanned using the FreeScan Trak Pro2. The system’s primary advantage is its ability to capture high-precision data without scan spray or extensive marker placement.

Monocoque data scanned by FreeScan Trak Pro2

After scanning, data is processed in a 3D inspection software, where engineers verify tolerances against design specifications. With the quality control lab integrated into the production facility, potential manufacturing deviations are quickly identified and corrected, preventing costly delays.

Monocoque inspection

“The FreeScan Trak Pro2 allows us to inspect complex carbon fiber structures faster and with greater accuracy…With real-time data, we can immediately address any deviations, ensuring a perfect fit for every component.”

— Ivan Radicevic, Quality Control Technician

The Benefits of Using FreeScan Trak Pro2 in Hypercar Quality Control

Bugatti-Rimac selected the FreeScan Trak Pro2 for its exceptional accuracy, speed, ease of use, and reliability:

Metrology-grade precision ensures every measurement meets strict tolerances.
High-speed scanning accelerates inspections, preventing production delays.
No scan spray or excessive markers simplifies workflow and saves time.
Seamless software operation ensures no bottlenecks in the software pipeline.
Reliability and expert support from SHINING 3D ensure uninterrupted operations.

FreeScan Trak Pro2 for hypercar monocoque quality control

“The FreeScan Trak Pro2 is 50% faster and 100% more accurate than its predecessor, giving us a major advantage in quality control.”

—Ivan Radicevic, Quality Control Technician

By integrating FreeScan Trak Pro2 into its metrology lab, Bugatti-Rimac upholds its commitment to engineering excellence, ensuring that every Nevera hypercar meets the highest standards of quality and precision.

Conclusion

In the hypercar industry, absolute precision is not optional—it’s essential. Bugatti-Rimac’s adoption of SHINING 3D’s FreeScan Trak Pro2 highlights the growing importance of high-end 3D scanning solutions in advanced quality control workflows. With unmatched accuracy, speed, and reliability, the FreeScan Trak Pro2 is an indispensable tool for manufacturers pushing the limits of performance.

Through strong collaboration with SHINING 3D, Bugatti-Rimac continues to set new benchmarks for innovation, quality, and customer satisfaction. At SHINING 3D, we are more than happy to support Bugatti-Rimac with cutting-edge technology to propel them to the next level of excellence.

Explore Shining3D metrology solutions

SHINING 3D offers a range of advanced metrology 3D scanners tailored to meet the needs of demanding industries and applications. From small parts like screws to large-scale objects like rocket engines, our 3D metrology solutions guarantee accurate data capture, reverse engineering, and top-tier quality con

Through strong collaboration with SHINING 3D, Bugatti-Rimac continues to set new benchmarks for innovation, quality, and customer satisfaction. At SHINING 3D, we are more than happy to support Bugatti-Rimac with cutting-edge technology to propel them to the next level of excellence.

Laser Handheld 3D Scanner

Handheld FreeScan Trio 3D Scanner

The FreeScan Trio 3D Scanner is a marker-free 3D scanner featuring 98 laser lines and a triple 5MP camera system...
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Metrology for quality control

Handheld FreeScan Trak Pro2 3D Scanner

The FreeScan Trak Pro2 is a 3D handheld scanner offering markerless optical 3D measurement with dynamic tracking for large workpieces....
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Laser Handheld 3D Scanner

Handheld FreeScan UE Pro 3D Scanner

The FreeScan UE Pro 3D Scanner is a handheld 3D scanner designed for metrology-grade 3D scanning, ideal for 3D CAD...
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Ashkhen Ovsepyan: Making Metal 3D Printing Accessible

Ashkhen — Thu, 10 Jul 2025 10:19:05 +0000

In an exclusive interview with TCT Magazine, Ashkhen Ovsepyan, Founder and CEO of California-based Additive Plus, reveals how her company’s new AO Metal printer line is dismantling cost barriers in metal additive manufacturing. Inspired by her first encounter with 3D printing 15 years ago (her inaugural print was a plastic keychain she still keeps), Ovsepyan is channeling that same sense of technological wonder into making metal AM accessible.

The Problem:
“Innovation should have unlimited resources or zero budget,” states Ovsepyan. Traditional metal printers—often costing $500K+—force users to ration machine time, stifling experimentation. This paradox fueled Additive Plus’ bold decision to develop its own systems after a decade as a reseller.

The Solution: AO Metal Series
Debuting at RAPID + TCT 2025, these U.S.-made, compact laser powder bed fusion (LPBF) systems start at $59,000—a fraction of competitor pricing. Three models target labs, universities, and small manufacturers:

A30 (30mm build)
A50 (50mm, blue laser + 900°C platform)
A100 (100mm, dual infrared/blue lasers)

Bundle 3D Printers

A30 Metal 3D Printer – High Precision & Durability

A compact LPBF system with one 200-watt laser for small series metal production.
- Technology:
  Metal LPBF
- Materials:
  Metal Powders
$59,000
Add to cart

Bundle 3D Printers

A50 Metal 3D Printer – High Precision & Durability

A compact LPBF system with 1x300W laser for small series metal production.
- Technology:
  Metal LPBF
- Materials:
  Metal Powders
$89,000
Add to cart

Bundle 3D Printers

A100 Metal DMLS 3D Printer for Sale – Explore the Best Metal Printers

A compact LPBF system with one 300-watt laser ideal for R&D issues.
- Materials:
  Metal Powders
$99,000
Read More

Breakthrough Capabilities:
Unlike any printers in their class, AO Metal systems feature:
🔹 Blue laser technology for printing reflective alloys (copper, gold, titanium)
🔹 Fully open architecture enabling material R&D freedom
🔹 900°C build chambers for advanced alloy development
🔹 Modular R&D Ecosystem (bundled with Verder’s CAMSIZER particle analyzer and ATO Lab Plus atomizer)

Market Impact:
Since launch, demand has been “overwhelming,” with Ovsepyan noting: “Customers need adaptable tools to test real-world applications without financial fear.” The printers address critical gaps:

🇺🇸 Local U.S. manufacturing/support for defense and regulated industries
💡 Democratized R&D via the $59K entry point
⚡ Integrated workflow from powder production → analysis → printing

Vision for the Future:
While larger systems (200-250mm builds) are under consideration, Ovsepyan remains focused on empowering innovators: “Success is seeing customers create previously impossible applications. That’s the kindergarten-level joy driving us.“

Read the Full Interview on TCT Magazine

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5 Ways Atomization Boosts US Metal AM Quality

Lianna Stepanyan — Wed, 27 Aug 2025 10:13:55 +0000

Metal additive manufacturing (AM) in the U.S. is growing fast, with aerospace, medical, and defense companies pushing for higher standards of precision and reliability. At the center of this progress is the quality of the metal powder.

Source: Stratiresearch

Atomization is the method that turns bulk metal into fine powders used in 3D printing. The way these powders are produced affects every layer of the build, influencing part density, surface finish, and overall performance. For U.S. manufacturers focused on consistency and stronger local supply chains, metal atomization technology is a competitive advantage.

This article explores five ways atomization raises the quality of metal AM parts, from flowability and particle size control to cleaner alloys and sustainable powder reuse.

1. Enhanced Powder Sphericity For Better Flowability

One of the main advantages of powder atomization is the ability to produce highly spherical metal particles. Shape matters; irregular powders tend to clump, resist smooth spreading, and create uneven layers during printing.

With metal atomization technology, particles form into near-perfect spheres that flow more easily across the build plate. This improves layer uniformity, reduces the risk of voids, and leads to denser final parts with smoother surfaces. The effect is clear in both laser-based and electron beam AM systems, where consistent powder flow directly impacts process stability.

Better flowability also makes powders easier to handle, store, and recycle. For manufacturers, this means fewer print failures, improved efficiency, and stronger confidence in repeatable results, whether producing a medical implant, an aerospace component, or a prototype in a U.S. R&D lab.

Source: Metal Additive Manufacturing Magazine

2. Controlled Particle Size Distribution

Source: Springer

How tightly sized your powder particles are can make or break metal AM results.
Too much variation in particle size means inconsistent melting. Larger particles take longer to absorb laser energy, while very small ones may vaporize or clump, leading to voids or uneven grains.

A recent technical review explains that particle size distribution (PSD) isn’t just a spec on a datasheet; it drives how powders feed, flow, and ultimately how densely parts form. Narrow PSD yields better process stability and repeatable build integrity, especially vital in aerospace, energy, defense, and medical sectors.

With atomization technology, you can engineer powders with a tight PSD consistently. Adjusting gas pressure, melt flow, nozzle design, or sonotrode vibration lets you dial in just the right distribution for laser or electron beam systems.

Read related resources:

How Atomization Technology is Transforming Metal Powder Production

Ultra-Spherical Copper & Alloy Powders for AM | Optimized Ultrasonic Atomization Process

3. Reduced Contamination And Oxidation

Oxygen, nitrogen, and other impurities are some of the most damaging variables in metal additive manufacturing. Even small amounts can weaken mechanical properties, reduce fatigue resistance, and compromise corrosion performance. This is especially critical in aerospace and medical applications, where failure is not an option.

Atomization technology addresses this challenge by producing powders in closed-loop, inert gas environments. Using gases such as argon or nitrogen prevents oxygen pickup during droplet formation and solidification. Studies show that powders atomized under inert conditions have lower oxygen content and fewer inclusions, which directly translates to improved ductility and longer service life of the printed parts.

In contrast, water atomization or open-air processes can introduce oxide films and trapped impurities, making powders less suitable for high-performance AM. For U.S. manufacturers, adopting inert gas metal atomization ensures that critical parts meet stringent quality standards while reducing the risk of costly failures.

4. Custom Alloy Development And Homogeneity

Bundle

AO METAL + ATO Lab Plus + Camsizer x2: R&D Bundle
- Technology:
  Ultrasonic atomization, Metal LPBF
- Materials:
  Metal Powders
Read more

Buy the AO METAL + ATO Lab Plus + Camsizer x2 and other atomizers with financing today!

Innovation in metal AM depends on access to new alloys. Standard steels, aluminum, and titanium cover many applications, but advanced industries require more: superalloys for turbines, biocompatible metals for implants, and high-temperature materials for defense.

Powder atomization technology makes it possible to produce experimental or proprietary alloys in small batches. Unlike mechanical blending, where powders can separate, atomization melts and solidifies the alloy as a uniform structure. The result is consistent chemistry and homogeneous microstructures that improve reliability in AM builds.

Studies show that alloys created by metal powder atomisation demonstrate stronger mechanical properties and better stability than blended powders, which often leave local weaknesses. That makes atomization a critical tool for R&D labs, universities, and defense programs advancing material science.

For U.S. manufacturers, producing and testing custom alloys domestically accelerates innovation, reduces dependence on imports, and secures supply chains.

5. Improved Powder Recycling And Sustainability

One of the practical challenges in metal AM is managing unused powder. Every build leaves residual material, and without stable properties, it can only be discarded, raising costs and creating waste.

With metal atomization technology, powders show more consistent morphology and chemistry across multiple reuse cycles. Spherical particles maintain good flow, while controlled particle size distribution helps powders spread and melt predictably even after several builds. Research confirms that atomized powders can be reused multiple times with minimal impact on density or mechanical performance.

This reliability lowers the cost per part and supports sustainable manufacturing goals. For U.S. companies, metal powder atomization also reduces dependence on imported materials by keeping more of the powder lifecycle domestic. In industries under pressure to cut waste and strengthen supply chains, powder recyclability is both an economic and strategic advantage.

Shaping The Future Of U.S. Metal AM With Atomization

Atomization is more than a powder production method; it is the backbone of quality in metal additive manufacturing. By improving particle shape, controlling size distribution, minimizing contamination, enabling custom alloys, and supporting recycling, it directly raises the reliability and performance of AM parts.

For the U.S., investing in local metal atomisation and powder atomization capabilities also strengthens supply chains and reduces reliance on overseas sources. It’s a step toward consistent quality, faster innovation, and more resilient domestic manufacturing

At Additive Plus, we help companies bring these advantages into their own workflows with advanced atomization systems, powder analysis tools, and metal 3D printers. If you’re ready to explore how atomization technology can improve your production quality, our team is here to guide you.

See Additive Plus’s Selection

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