Made to order
- Install, commissioning & training Set up and dialed in at your site
- Applications engineering Crucible-vs-rod feed and melt setup for your alloys
ATO Induction Melting System (IMS) for Ultrasonic Metal Atomizers
Induction melting in a crucible for your ATO ultrasonic atomizer — atomize feedstock of any shape and keep low-melting-point elements in the alloy.
- 200 cm³ standard crucible · larger on request
- Irregular feedstock, scrap and rods · compatible with ATO rod feeders
- Installation, on-site operator training and US service included in every quotation
- Lead time 8–12 weeks · 12-month warranty
What your process engineer actually checks
Induction melt for demanding alloys
Induction melting reaches and holds the temperatures that high-melting-point and refractory alloys need, expanding the range of materials the atomizer can turn into spherical powder beyond what arc melting covers.
Clean, controlled melting
Controlled induction heating gives a stable, repeatable melt with less contamination, feeding the ultrasonic atomizer consistent material for consistent powder.
An applications engineer on the line
We run ultrasonic atomization and melting in-house through ATO Lab.
- IMS induction melting module for your ATO ultrasonic atomizer
- Standard 200 cm³ double-layer crucible; larger crucibles on request
- Pressurized molten-metal feeding system, precise temperature measuring and digital monitoring
- Universal ATO Powder Container for collection and transfer to ATO Sieve
- ATO Remote Control module for setting key parameters from a tablet (optional)
- Installation and on-site operator training — included in every quotation
What the ATO Induction Melting System is
The ATO Induction Melting System (IMS) is an optional, easy-to-swap module from 3D Lab that adds induction melting to the ATO ultrasonic metal atomizers. Instead of melting the tip of a rod or wire, it melts the charge in a crucible and delivers the molten metal to the sonotrode through a pressurized, precise feeding system, inside a sealed chamber filled with shielding gas. A precise temperature measuring system and digital monitoring keep the melt where the alloy needs it.
Two things follow. Feedstock no longer has to be a rod or a wire: irregular pieces, recycled scrap and off-cuts can be atomized. And alloys with low-melting-point elements lose less of them on the way to powder. The module is compatible with the standard ATO rod feeders, so one atomizer can run either a crucible or rods, whichever the material calls for.
Specifications
| Type | Induction melting expansion module, optional and easy to swap |
| Fits | ATO ultrasonic metal atomizers; listed by 3D Lab among the optional modules of the ATO Lab, and ATO Sparq offers induction melting |
| Melting | Induction, in a sealed chamber filled with shielding gas |
| Crucible | 200 cm³ standard · larger on request |
| Crucible design | Double-layer, for insulation and steady processing |
| Melt delivery | Pressurized, precise molten-material feeding system |
| Temperature | Precise temperature measuring system |
| Monitoring | Digital monitoring system |
| Feedstock | Irregular shapes, scrap and rods; compatible with standard ATO rod feeders |
| Powder collection | Universal ATO Powder Container, protective gas atmosphere, links to ATO Sieve |
| Remote operation | ATO Remote Control module — key parameters from a tablet (optional) |
| Operation | One operator |
| Design | Modular and compact, low space requirements |
| Manufacturer | 3D Lab, Poland |
| Installation and training | On site, included in every quotation |
| Warranty | 12 months, US service engineers |
| Lead time | 8–12 weeks |
What it changes in your powder workflow
The IMS is the feed path to choose when the material, not the machine, sets the limits:
| Feedstock form | scrap, irregular pieces and off-cuts — no rod casting or wire drawing first |
| Volatile elements | evaporation of low-melting-point elements minimized, chemistry stays closer to the charge |
| Yield | process efficiency significantly higher than a standard configuration, according to 3D Lab |
| Purity | melting under shielding gas in a sealed chamber for high chemical purity |
| Material recovery | AM scrap and rejected parts go back into powder — a circular loop |
| Alloy development | design custom alloys and atomize them in small crucible charges |
3D Lab built the IMS for research labs and additive manufacturing centers that want to widen the range of materials they atomize and scale their own powder production.
How the IMS runs
Because the IMS also works with the standard ATO rod feeders, you keep the simple rod setup for routine alloys and switch to the crucible when the material calls for it.
Where the IMS stops — and what to take instead
The IMS is a module, not a standalone furnace or atomizer: it needs an ATO ultrasonic atomizer such as the ATO Lab or ATO Sparq, and each run is bounded by the crucible charge — 200 cm³ standard, larger on request. If your feedstock is already wire and you want long uninterrupted runs, the ATO Wire Feeding System fits better. For cast rods, take the Single Rod or Multi Rod Feeding System. To cast feedstock rods yourself, there is the ATO Cast induction vacuum casting furnace. And for reactive powders that must be made safe to handle after atomization, add the ATO Passivation Module.
Make your own powder, measure it, print it
The IMS widens what goes into an ATO ultrasonic atomizer; the rest of the loop stays the same. Atomize the alloy into spherical powder in the 20–120 µm range, check size distribution and sphericity on a Microtrac CAMSIZER X2+, print it on an AO Metal LPBF printer, and repeat. The atomizer, analyzer and printer are also offered together as the R&D Bundle. If you would rather have powder than equipment for now, see our custom alloy metal powder.
Powder made on ATO
Alloys 3D Lab has atomized with the Induction Melting System. Images: 3D Lab material reports and case studies.
Material reports from 3D Lab
Alloys 3D Lab has atomized with the Induction Melting System and documented: copper, Ampcoloy 972, bronze, gold, Incusil ABA, AlFe, aluminum 6060 and the magnesium alloys WE43 and ZX00 — particle size distribution (D10/D50/D90), circularity and micrographs at ×100 and ×1000.
See it running in California
You can see an ATO atomizer running in California, at UC Irvine (UCI). Book your visit on our visit page. Book a visit at UC Irvine
In pictures
Availability, payment and delivery
Why buy it through Additive Plus
What usually stops people — and the honest answer
Ready when you are
| Brand | 3D Lab |
| Country of origin | Poland |
Product videos
We run custom batches too. Try before you build the capability.
Want to validate an alloy before buying the system? Our ATO lab runs a custom batch for you in 3–4 weeks — biocompatible, refractory, proprietary — so you see real powder before committing to in-house atomization.
Other products teams run alongside ATO Induction Melting System (IMS) for Ultrasonic Metal Atomizers
Ultrasonic metal powder atomization with AI-guided setup — 20–120 µm spherical powder, oxygen below 10 ppm, two camera views and remote supervision of several units.
- AI suggests parameters for standard and new alloys
- Reactive, refractory and standard alloys from wire, rod or scrap
- Installation, training and US service included · free powder samples
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation included
Ultrasonic and brush cleaning of wire and rod feedstock before it reaches the ATO atomizer — set the cleaned length or weight and let it run.
- Wire on spools, plus a rod mode for the Single Rod Feeding System
- Automatic and manual modes · integrated safety sensors
- Installation, training and US service included · free powder samples
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation included
Continuous, automated wire feed for your ATO ultrasonic atomizer — standard welding-market wire, reactive or non-reactive, on extended spools.
- Extended spools · fewer changes, longer runs
- Reactive and non-reactive wire from the welding market
- Installation, on-site operator training and US service included in every quotation
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation included
Longer atomization runs from rods on your ATO ultrasonic atomizer — round rods of 4 to 10 mm in self-locking collets, up to 1200 mm per load.
- Up to 1200 mm of rod per load with the extended tube container
- Round rods 4–10 mm · collets 4, 6, 8 and 10 mm
- Installation, on-site operator training and US service included in every quotation
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation included
Cast your own feedstock rods for ATO atomizers — from any alloy you design or from AM scrap — with pre-melt purification and induction melting under vacuum.
- Built-in resistance furnace purifies the charge before casting
- 120 mm rods for the Revolver Rod Feeding System · re-cast AM scrap
- Installation, training and US service included · free powder samples
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation included
Atomize your own alloys from a single rod on an ATO ultrasonic atomizer — 1 to 10 mm in diameter, up to 110 mm long, cast rods welcome.
- Rods 1–10 mm, 4–6 mm recommended, up to 110 mm long
- Cast rods · upgradeable to a Custom Shape Feeder
- Installation, on-site operator training and US service included in every quotation
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation included
Make freshly atomized reactive powder safe to open — automated, controlled oxygen dosing builds a thin protective oxide layer inside the 3D Lab powder container.
- Automated passivation cycle of 1–2 hours, depending on the material
- Designed for opening the container with no ignition or explosion risk
- Installation, on-site operator training and US service included in every quotation
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation included
Atomize up to 10 rods in one setup on your ATO ultrasonic atomizer — automated rod change in protective gas, with control of feed speed and rod rotation.
- Up to 10 rods of 120 mm — the ATO Cast rod size
- Automated rod change in protective gas · feed speed and rotation control
- Installation, on-site operator training and US service included in every quotation
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation includedWhat our customers say
“Harry and team were professional, effective communicators as we set up the order, then they executed quickly and produced an amazing product for us at a very competitive price. Am looking forward to our next print w Additive Plus!”
“Great 3D printing service and the resin parts look super smooth and clean. Really happy with how everything turned out!”
“Harry was very professional and helped me out with my 3D printing needs and explained what options I have in terms of filaments such as PEEK. Highly recommended.”
“I needed a 3D enclosure printed urgently in a specific time period, they did great!”
Common questions
Don't see yours? Email [email protected] — NDA standard, typical reply within 4 hours.
What is the ATO Induction Melting System?
How is the IMS different from the rod and wire feeders?
What crucible size does the IMS use?
Which atomizers is the IMS compatible with?
Does the IMS help with material recovery?
Can I atomize alloys with volatile elements?
Does the IMS increase atomization yield?
How is the powder collected?
Can the IMS be operated remotely?
Which alloys can I make with the IMS?
How much does the ATO Induction Melting System cost?
What is the lead time and warranty for the ATO Induction Melting System?
Can I get a free powder sample or a trial atomization?
Can I see an ATO atomizer running?
Place your order, or talk to an engineer first
Order ATO Induction Melting System (IMS) for Ultrasonic Metal Atomizers direct, or talk to materials engineer