ATO Sparq | AI-Powered Ultrasonic Metal Powder Atomizer
On-demand production of spherical metal powders — smarter, faster, scalable.
ATO Sparq is an AI-powered ultrasonic metal powder atomizer designed for laboratories and production environments that need fast material qualification, repeatable powder quality, and full control over particle size distribution.
Produce exactly the powder you need — when you need it.
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Technology:
Ultrasonic atomization
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Description
Make High-Quality Spherical Metal Powders In-House
ATO Sparq produces high-sphericity metal powders with excellent flowability and AI-controlled Particle Size Distribution (PSD) tailored to your target Additive Manufacturing process.
High sphericity & smooth surface
Controlled PSD for consistent printing results
Low oxygen content — suitable for reactive alloys
Repeatable results across batches and machines
AI-Guided Atomization. Zero Guesswork.
What sets ATO Sparq apart is its AI-powered process control.
The system analyzes atomization parameters and guides setup — even for completely new alloys. This dramatically reduces trial-and-error, speeds up development, and ensures stable powder quality from the first runs.
AI-assisted parameter selection
Fast setup for new materials
Consistent PSD across production cycles
Compact, Self-Sufficient & Scalable
ATO Sparq is engineered as a compact, self-sufficient atomizer with a minimal footprint — ideal for labs, R&D centers, and production floors.
Remote monitoring and control allow one operator to supervise multiple atomizers, enabling scalable powder production without increasing headcount.
Small footprint
Reduced infrastructure requirements
Remote control & monitoring
Multi-atomizer production ready
ATO INSIDE
Take Control Over Powder Particle Size
ATO Sparq features multi-frequency ultrasonic atomization, allowing precise tuning of powder size ranges for different applications.
Select the frequency module to match your process:
Fine powders for LPBF / SLM
Medium fractions for Binder Jetting & MIM
Coarser powders for DED, laser cladding & PM
One system — multiple PSD targets.
Sustainable & Cost-Efficient Powder Production
Stop buying hundreds of kilograms just to qualify a new material.
ATO Sparq enables on-demand powder production, reducing material waste and qualification costs. Recycle in-house feedstock and scrap into new powder batches and close the material loop.
On-demand batch sizes
Scrap & feedstock recycling
Lower material qualification costs
Reduced environmental footprint
Versatile Material Compatibility
From standard AM alloys to exotic chemistries — ATO Sparq handles both reactive and non-reactive metals.
AI-guided setup and modular melting stabilize atomization even for challenging materials, making Sparq a powerful tool for materials development and advanced manufacturing.
list of successfully atomized ALLOYS
Steel is the most widely used material in almost all industries due to its low price, high mechanical properties and a wide range of heat treatments that can help tailor the material for individual purposes. The atomization process of steel is one of the simplest and most balanced in terms of quality, yield and process stability. Its characteristics allow it to be used as a primary benchmark material for the ultrasonic atomization process. The distribution of the powder is very homogeneous with a narrow range of metal powder, which is very desirable for some manufacturing methods.
ATOMIZED ALLOYS ON ATO
- 42CrMo4
- AMS5832
- Fe 99,5%
- FeMn
- PH177 Garba
- SS304
- SS316L
Titanium is one of the most promising materials of the 21st century, having one of the highest values of strength to density and corrosion resistance. Similar to steel, it can be easily atomized using ultrasonic atomization. The process can be very stable which has immense potential for automation. Considering the high prices of titanium alloys and its powders, ultrasonic atomization has one of the best commercial perspectives. Nevertheless, one of the main challenges is the rate of absorption of oxygen and nitrogen, which places additional requirements for the atomization process conditions.
ATOMIZED ALLOYS ON ATO
- Ti OCT 1-90013-81
- Ti5Al2.5Sn
- TiAl
- TiMoSi
- Titanium Gr.1
- Titanium Gr.2
- Titanium Gr.5 (Ti6Al4V)
Nickel-based alloys are mainly used in the aerospace industry due to their high temperature and corrosion resistance combined with good ductility and strength. The atomization of the material is very stable, similar to steel and titanium. Oxygen pick-up is exceptionally low, and the material is homogeneous. Due to these advantages, ultrasonic atomization seems to be a good and efficient method for scrap recycling. Some international companies may be interested in implementing ultrasonic atomization to reduce their carbon footprint and increase the ESG rating.
ATOMIZED ALLOYS ON ATO
- Inconel 625
- Inconel 718
- Ni 99%
- NiTi
- NiTiHf
Aluminum is one of the most commonly used non-ferrous alloys due to its low density, relatively high strength and good corrosion resistance. Atomization of the metal and its alloy is quite challenging due to several issues. However, the powder meets the requirements for most 3D printers with a sphericity of 0.93 and an eq. grain diameter of approximately 50 µm. One of the main challenges with aluminum and its alloys is their affinity for oxygen, which creates a large surface tension between the molten metal and the sonotrode tip which decreases the contact zone. Furthermore, a thin layer may still be present on the surface of the powder. Based on the research conducted, higher frequency allows for a more stable atomization process that can be performed with minimal operator interference.
ATOMIZED ALLOYS ON ATO
- Al 99,99%
- Al4047
- Al5183
- Al7075
- AlCoCrFeNi
- AlMg
- AlMgCu
- AlMgSc
- AlSi10Mg
The lightest construction material which has decent strength and the highest specific strength for metal alloys. Magnesium alloys can be used where weight reduction is a key feature. The atomization of magnesium tends to be challenging, but by optimizing the process it is possible to obtain powder with high sphericity. Higher frequency piezoelectric generators can further stabilize the process. It is also worth noting that the problem with most magnesium alloys is very rapid oxidation, which also applies to atomized powder. Magnesium powder is highly reactive and the ATO Lab Plus system has one of the best coating systems which increases the safety of the process.
ATOMIZED ALLOYS ON ATO
- MgAl9Zn1
- AZ31
- WE54
This group includes the most resilient materials that are hard to manufacture and form using conventional technologies. The most common materials in this group are tungsten, molybdenum and tantalum. Ultrasonic atomization enables to produce a fine powder suitable for most applications. It is worth mentioning that 3D Lab has dedicated features that reduce the wear of the working chamber, which is an issue for all refractory materials. The atomization process is stable and can be partially automated.
ATOMIZED ALLOYS ON ATO
- Nb 99%
- Ta 99%
- W90Ni7Fe3
- MoSi2
Gold, platinum and silver can be successfully atomized to produce fine metal powders. This opens new shaping possibilities where the only limit is the designer’s imagination. Furthermore, by using ATO Noble it is possible to achieve zero waste production, which is the most important feature in the jewelry industry. It is also worth mentioning that the chemical composition remains the same after atomization, which helps to maintain the right precious metal standard.
ATOMIZED ALLOYS ON ATO
- Ag 99%
- Au 9ct
- Au 18ct
- Au 99,99%
- Au 99,99%
- Ir 99%
- Pt alloys
Copper and its alloys are best known for their electrical and thermal conductivity. The material has high resistance to corrosion and is a semi-precious material. The material enforces the use of higher currents despite relatively low melting temperature. Nevertheless, metal powder has remarkably high sphericity and homogeneity. Atomization of zinc-containing brass can be challenging due to fuming at high temperatures. Careful parameter optimization is required.
ATOMIZED ALLOYS ON ATO
- CuAlNiFe
- CuCrZr
- CuM1E
- CuMnAl
- CuNi3Si
- CuSn
High entropy alloys are being developed at many research institutions. The results indicate that some HEAs have significantly better strength-to-weight ratios, with higher levels of fracture resistance, tensile strength, and corrosion and oxidation resistance than conventional alloys. The atomization of HEA is highly dependent on the chemical composition of the material. It is easier to atomize materials that are easy to melt and have relatively low surface tension. Depending on the chemical composition of the alloy, the melting tip material core must be selected individually.
ATOMIZED ALLOYS ON ATO
- CoCrFeMo
- NiCrFe
- FeNiCrMo
- CoCrFe
- FeNiAlCr
In addition to the common metals, we have successfully atomized metals for the semiconductor industry, such as MoS2 and others. Spherical metal powders were obtained in laboratory quantities, which can be further processed by special AM processes. We have also had success with some zirconium bulk metallic glasses, although in small quantities. Other meltable and weldable materials can be atomized with appropriate process parameter selection. Based on melting temperature, affinity to oxygen, chemical composition requirements, it is possible to obtain the appropriate atomization parameters.
ATOMIZED ALLOYS ON ATO
- MoS2
- B4C
ULTRASONIC POWDER ATOMIZATION TECHNOLOGY
Ultrasonic vibration technology is used to break molten metal into small droplets, which rapidly solidify into metal powder in an inert gas atmosphere. The metal powder size produced depends on the frequency of the ultrasonic waves, with higher frequencies producing smaller particles and lower frequencies producing larger particles. Factors affecting particle size and distribution are viscosity, density, ultrasonic amplitude and atomizer design. Ultrasonic atomization of metal powder using ATO technology is a process in which metal powder is melted using an electric arc. Ultrasonic vibrations are then transmitted into the molten metal, creating capillary waves. These waves eject metal droplets, which are rounded and cooled before being collected and sorted. The result is almost perfectly spherical metal droplets.
ato patents
Part of the ATO Metal Powder Production Suite
ATO Sparq integrates seamlessly into the ATO Metal Powder Production Suite — a complete ecosystem for metal powder production and handling.
From casting and atomization to sieving, ultrasonic cleaning, and material handling — everything works together to maximize efficiency and powder quality.
The ATO atomizers configuration is flexible and based on a patented ultrasonic atomization technology. The system can be easily customized to meet the individual needs of the customer. ATO is a modular system with the future potential to operate with sets of many units in an interconnected network.
Bring metal powder production into your lab.
Gain control over particle size, material quality, and development speed.
Frequently Asked Questions (FAQ)
ATO Sparq is an AI-powered ultrasonic metal powder atomizer designed for laboratories and production environments. It enables on-demand production of high-quality spherical metal powders with controlled particle size distribution (PSD), low oxygen content, and repeatable batch results.
ATO Sparq uses ultrasonic vibrations applied to molten metal to create capillary waves that eject fine droplets. These droplets rapidly cool in an inert gas atmosphere and solidify into nearly perfectly spherical metal powder particles.
ATO Sparq combines ultrasonic atomization with AI-guided process control. This allows precise PSD tuning, faster setup for new alloys, smaller batch sizes, and significantly reduced trial-and-error compared to conventional atomization systems.
AI-guided atomization analyzes process parameters and recommends optimal settings for each material. This helps users achieve stable atomization and consistent powder quality even when working with completely new or challenging alloys.
Yes. ATO Sparq is optimized for Additive Manufacturing and can generate powder fractions suitable for LPBF/SLM, Binder Jetting, MIM, DED, laser cladding, and Powder Metallurgy applications.
ATO Sparq uses multi-frequency ultrasonic modules to precisely tune particle size ranges. Higher frequencies produce finer powders, while lower frequencies generate coarser particles, allowing one system to support multiple PSD targets
ATO Sparq supports fine powders for LPBF/SLM, medium fractions for Binder Jetting and MIM, and coarser powders for DED, laser cladding, and PM — all within a single modular platform.
ATO Sparq supports both reactive and non-reactive metals, including steels, aluminum alloys (AlSi7Mg, AlSi10Mg, Al-Mg), and other advanced AM alloys. AI-assisted setup stabilizes atomization even for difficult chemistries.
Yes. The system operates in an inert atmosphere and delivers low oxygen content powders, making it suitable for reactive materials and high-performance alloys.
Absolutely. ATO Sparq is designed for on-demand production, enabling small batch sizes for material qualification, R&D, and prototyping without purchasing large volumes of commercial powder.
ATO Sparq produces powders with high sphericity and smooth surfaces, resulting in excellent flowability and consistent printing performance.
AI-controlled process parameters ensure repeatable PSD and powder quality across batches and machines, supporting reliable production and material development.
Yes. ATO Sparq allows in-house recycling of feedstock and metal scrap into fresh powder, helping close the material loop and reduce waste.
By enabling on-demand production and recycling, ATO Sparq lowers material waste, reduces qualification costs, and minimizes the environmental footprint associated with external powder sourcing.
Yes. Its compact footprint, fast material changeover, and AI-guided setup make it ideal for laboratories, universities, and industrial R&D centers.
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Yes. ATO Sparq supports scalable production with remote monitoring and control, allowing one operator to supervise multiple atomizers. |
ATO Sparq is engineered with a compact, self-sufficient design that requires minimal infrastructure, making it suitable for space-constrained labs and production floors.
Yes. The system includes remote monitoring and control capabilities, enabling multi-atomizer production without increasing staffing.
ATO Sparq supports additive manufacturing, materials development, aerospace, automotive, research institutions, and advanced manufacturing environments requiring precise metal powders.
Yes. By producing powder in-house and using AI-guided parameter selection, ATO Sparq dramatically shortens material development cycles and reduces dependency on external suppliers.
Consistent ultrasonic atomization combined with AI-driven parameter control ensures stable PSD and uniform powder quality from the first run through ongoing production.
Yes. ATO Sparq is part of the ATO Metal Powder Production Suite and integrates with casting, sieving, ultrasonic cleaning, feeding systems, and material handling modules.
Yes. The modular architecture allows multiple atomizers to operate in an interconnected network, supporting future scale-up.
Yes. It works seamlessly with ATO casting systems, sieving stations, ultrasonic cleaners, feeding modules, and passivation units for a complete powder production workflow.
ATO Sparq supports multiple feeding systems, including rod feeding, wire feeding, and multi-rod configurations, depending on your material and production needs.
Yes. ATO Sparq is currently in stock and available for quotation.
Yes. You can request a quote directly from the product page, and the Additive Plus team can help configure ATO Sparq to match your material and production requirements.
- Brand 3D Lab
- Country of origin Poland
- Process Metal powders production
- Technology Ultrasonic atomization
- Meltimg method TIG, Induction, Plasma
- Sonotrode type Half-wave nanoalloy sonotrode - patent pending
- Inert gas flushing method Vacuum pump
- Cooling method Liquid
- Processable materials Non-reactive & reactive alloys (e.g. Ti, Al., Zr alloys, intermetallics e.g. Zr-based bulk metalic glass TiAl, NiAl, NiTi) and other refractory metals
- Powder quality Low oxygen content, Narrow PSD, High flowability, Spherical particle shape
- PSD (particle size distribution) 20-120um
- Powder collecting system Cyclone
- Protective atmosphere preparation time <15 min.
- Input material Irregular, Rods, Scrap, Wire
- Certification CE
- Ultrasonic frequency 20, 35, 52, 72
- O2 level <10 ppm
- System throughput up to 0,3l/h
- Weight 600 kg.
- Dimensions 1997x813x1626 mm, 78.62x32.01x64.02 in
- Air supply Compress air station
- Inert gas Argon
- Power supply 400V, 20KVA / 3 phase
- Cleaning unit Ultrasonic cleaner (ATO Clean)
- Powder recycling system Sieving unit (ATO Sieve)
- Water cooling External chiller
- Warranty 12 months
- Material Aluminium, Copper, HEA alloys, Magnesium, Nickel, Reactive metals, Refactory metals, Stainless Steel, Titanium
Materials
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Aluminium
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Copper
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HEA alloys
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Magnesium
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Nickel
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Reactive metals
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Refactory metals
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Stainless Steel
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Titanium
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