How small a batch can ATO realistically run?+
A single gram of feedstock produces a meaningful batch — the practical lower limit is geometric (you need enough material to form and feed), not a mass minimum. That's the fundamental difference from gas atomization, which needs kilograms to be economical. Many labs run 1–5 gram screening sessions before committing to a larger batch.
Can ATO process scrap, chips, and machining waste?+
Yes — it's one of the most valuable capabilities. Wire and rod are standard inputs, but clean scrap, turnings, chips, and failed prints can all be atomized. For costly alloys like titanium or Inconel, closing the loop on scrap changes the economics. The main requirement is that scrap be clean and free of contaminants; we'll review your specific profile on a discovery call.
Can ATO handle my specific alloy?+
It depends on the melt module, so we match the module to your alloy. The TIG and plasma melts cover Ti, stainless, Ni, Inconel, and high-temperature and refractory systems. The Induction Melting System (IMS) covers copper, aluminium, and other lower-melting alloys up to roughly 1700 °C — at the highest atomization rate in the family and with the cleanest chemistry, and it lets you melt a custom charge and atomize it in one workflow. ATO Noble covers Au, Ag, Pt, Pd, and Ir with under 1% loss. For exotic or proprietary alloys we run a trial first: if it melts into wire, rod, or a charge, we can usually atomize it — and we'll tell you honestly if we can't.
What's the rate of atomization, and how much powder per run?+
Two separate things, and they're often confused. Batch size is your choice — you set it by how much feedstock you load, and there is no minimum that makes a run worthwhile. Rate reaches several kilograms per hour and depends on the alloy and the melt module: an easily-melted alloy runs faster than a refractory one, and induction melting gives the highest rate of all because it feeds the melt continuously. We'll give you a realistic rate for your specific alloy on the call.
How is ATO different from other lab atomizers?+
Three things, all operational: maturity, control, and support. ATO has been deployed in the US since 2018 — the longest field record in the category — and 3D Lab holds the US patent on ultrasonic atomization for AM powders. The particle size is genuinely controllable rather than fixed, and the swappable melt modules mean one platform covers everything from copper to refractory systems. And because Additive Plus services it from Los Angeles, you get local installation, training, and support instead of a transatlantic queue. The best comparison is a live demo in Irvine — bring your wire and see your own result.
What do installation and training involve?+
A standard install is 2–3 days on-site with operator training included, and your first powder batch is produced during commissioning. Additive Plus provides US-based service from Los Angeles — no waiting on engineers from Poland, no time-zone gaps. Ongoing support is by phone, video, or on-site visit, and annual maintenance visits are available and recommended.
Can we trial it before committing?+
Two ways. A trial run: ship us your wire, rod, or scrap, and you get a full PSD analysis report within a week. Or a live demo in Irvine, California: come watch a run, ideally on your own material. Most trial customers convert to a full system within the same quarter.
Is financing or grant support available?+
Yes. We work with equipment-financing partners for qualified organizations, and universities and national labs frequently fund ATO through capital-equipment grants. We provide documentation for NSF, DOD, and institutional applications — if you're in the planning phase, reach out early and we'll support it with specs, pricing letters, and reference contacts.
