Powder Analysis and Manufacturing with Microtrac, ATO Lab Plus & AO Metal – July 2025

Additive Plus invites you to an exclusive Open House Event on either July 29 or 30, 2025, spotlighting the latest in Microtrac particle characterization and 3D printing technologies. Hosted at our Gardena, CA facility, this two-day event includes hands-on demos, technical presentations, and networking with field experts.

Additive Plus invites you to an exclusive Open House Event on either July 29 or 30, 2025 (choose your preferred day). Hosted at our Gardena, CA facility, this identical one-day program runs twice, featuring:

• Hands-on demos of Microtrac particle characterization and 3D printing technologies
• Technical presentations
• Networking with field experts

Same content both days—select the date that fits your schedule!

Experience live demonstrations of Microtrac’s SYNC, BEL, CAMSIZER, DLS + Zeta, Turbiscan, and more. We’ll also showcase the ATO Lab Plus and AO Metal 3D Printer, providing a full look at our R&D Instrumentation Bundle.

Whether you’re a materials scientist, QA professional, or engineer in additive manufacturing, this event is designed to help you elevate your lab’s precision, speed, and innovation.

Lunch provided.

Registration is free – secure your seat today!

Daily Agenda – Microtrac Product Spotlight

9:30 AM – Welcome & Introductions
Kick off the day with a welcome from the Additive Plus team and an overview of Microtrac’s solutions for particle and materials analysis.

10:00 AM – Technical Presentation
“Laser Diffraction Technology and Applications”
Presented by Cathy Yang, Additive Plus
Explore the Microtrac SYNC system’s hybrid capabilities—combining laser diffraction and dynamic image analysis for wet and dry samples from 10 nm to 2 mm.

10:45 AM – Technical Presentation
“Unlocking the Power of the R&D Instrumentation Bundle”
Presented by Ashkhen Ovsepyan,  Additive Plus
Learn how the ATO Lab Plus, CAMSIZER, and AO Metal 3D Printer work together as a versatile R&D bundle—ideal for labs focused on additive manufacturing, materials testing, and process development.

11:15 AM – Technical Presentation
“Analyzing Porosity, Density, and Catalytic Activity of Materials”
Presented by Sai Krishna Katla, Ph.D.
Gain insights into BEL’s advanced instrumentation for pore structure, surface area, and catalyst behavior—critical for industrial R&D and materials science applications.

12:00 PM – Networking Lunch Provided

1:00 PM – Live Instrument Demonstrations
Explore hands-on demos with the following platforms:

• SYNC (Laser Diffraction & Image Analysis)
• BEL Instruments (Gas Sorption, Pycnometry, Catalysis)
• DLS + Zeta (Size and Charge Measurement)

2:00 PM – Technical Presentation
“Advancing Nanoparticle Characterization: Accurate Size and Charge Measurement at High Concentration”
Presented by Prashun Roy, Ph.D., Microtrac
See how the Flex and Stabino systems provide high-resolution analysis of zeta potential and particle size at high concentrations—perfect for battery research, pharmaceuticals, and coatings.

3:00 PM – Live Instrument Demonstrations Continue

• CAMSIZER (Granular Particle Analysis)

Turbiscan (Stability and Dispersion Testing)

The Importance of Particle Analysis with CAMSIZER X2

The cost for the raw powder materials is an important factor in the manufacturing process. Only a very small amount of the powder forms the component. The rest of the powder bed, which has not been sintered, is recycled. The used material however may contain an unwanted amount of oversized, fused particles. Also, the shape of the particles could be different from the original powder. It might be necessary to screen the recycled powder to remove the oversized particles and blend it with fresh powder. Therefore, it is essential to check the quality of the recycled powders.
The CAMSIZER X2 is the perfect tool to analyze the particle size and shape of these powders, thus characterizing the raw material in the most comprehensive way. Even smallest amounts (<0.01%) of out-of-spec particles are detected. This ensures consistent quality of the manufactured products.

Typical sample materials

The following metal powders can conveniently be analyzed with the CAMSIZER X2: aluminum, cobalt, chromium, inconel, manganese, olybdenum, nickel, steel, titanium, tungsten, silver, gold and respective alloys. The best approach is to use dry dispersion with the X-Jet module  at a moderate dispersion pressure of 20 kPa.

The X-Jet dry dispersion module of the CAMSIZER X2 guarantees effective, yet gentle dispersion. Particles are measured in an air flow

The X-Jet dry dispersion module of the CAMSIZER X2 guarantees effective, yet gentle dispersion. Particles are measured in an air flow

Example 1: Comparison of laser diffraction and CAMSIZER X2

In the past, particle size analysis of metal powders was typically done by sieve analysis or laser diffraction. However, the method of Dynamic Image Analysis (DIA) allows a better understanding of the material properties, as length and width of the particles are detected independently. In contrast, laser diffraction analyzers calculate only one “size” parameter. The calculation algorithms of the laser instruments, irrespective of the brand or model, are based on a simple sphere model. The real shape of the particles is ignored and only the “equivalent diameter” is calculated. For irregularly shaped particles, laser diffraction analyzers often mix and misinterpret the data obtained from particle length and particle diameter, thus overestimating the percentage of large particles and pretending a wide size distribution.
Smallest amounts of oversized material, even below 0.01% Vol., are reliably detected by the CAMSIZER X2 as the measurement principle is based on the detection of individual particles in thousands of pictures per measurement. If a particle is captured, then the data of this particle is included in the measurement result, even if there is only one particle of a particular size and shape in the whole sample (“needle in a haystack”).
Laser diffraction analyzers detect an averaged scattering signal from all particles simultaneously. Small quantities of oversize or undersize particles are only included in the results if the amount of these particles exceeds the detection limit of typically about 2% Vol. Below this limit the signal is treated as noise and ignored by the software. Consequently, a laser diffraction analyzer does not detect oversized particles safely and reliably. Both sieve analysis and CAMSIZER X2 offer much better sensitivity.

Typical CAMSIZER X2 images of irregularly shaped metal particles of different sizes.

The CAMSIZER X2 provides information on particle width (red), particle length (blue) and the equivalent circle diameter (green).
The x50 value of the latter is usually more or less similar to the measurement of the laser particle analyzer (black*). The laser diffraction analyzer and the CAMSIZER X2 width measurement show a similar distribution for small particles. The percentage of oversize particles detected by the CAMSIZER X2 is in very good agreement with the results of sieve analysis. (orange *) whereas the laser sizer calculates too many large particles compared sieve analysis.

Example 2: Titanium and steel powder

Titanium powder is used, for example, in the aerospace industry. Our example shows two sets of measurements of two powders with different size distribution. The CAMSIZER X2 measurements demonstrate excellent reproducibility and agreement with sieve analysis results.
Note that each measurement of the steel powders took less than 20 sec. Two metal powder samples (titanium and steel) measured with the CAMSIZER X2 using the X-Jet dry dispersion module with 20 kPa dispersion pressure. the four measurements of the steel powder (different shades of red) took less than 20 seconds each. The reproducibility is excellent as can be seen from the almost perfect overlap of the four curves. The same can be said for the two titanium powder measurements (light blue and dark blue), which also agree perfectly with sieve results (black*).

Example 3 – Fine Metal Powders

Even close to the detection limit of 1 μm, the Camsizer X2 offers better resolution and sensitivity than a laser particle sizer. These types of powders are typically used in Metal Injection Molding (MIM) processes.

Two measurements of fine metal powders with a d50 value of 4.5 μm and 5.2 μm measured in dry dispersion mode. The CAMSIZERX2 analyzes fine powders down to 1 μm with excellent resolution, repeatability and sensitivity

Elevate Your 3D Printing with Additive Plus

The CAMSIZER X2 is ideal for determining the particle shape and particle size distribution of fine metal powders. Especially in modern powder metallurgical processes such as additive manufacturing, dynamic image analysis provides valuable information for the usability of both raw materials and recycled material. Particularly noteworthy are the short measuring times, the high sample throughput, the reliable detection of even the smallest amounts of oversize, and the finding of particles that deviate from the desired shape.

If you’re ready to take your 3D printing projects to the next level, Additive Plus is here to help. With over 10 years of experience, we specialize in helping clients integrate and optimize 3D printing technologies seamlessly into their operations.

Our curated portfolio features industry-leading brands like Farsoon Technologies, Kings3D, offering a wide range of materials and services to meet diverse needs. From design to consulting, we provide the expertise and tools to bring your ideas to life.

FAQ

Particle size and shape are critical parameters that influence the flow behavior of powders, the operating conditions of the printer, and the properties of the final product. Round particles in a narrow size range typically flow better and allow for more homogeneous deposition. However, if the size range is too narrow, it can lead to lower packing density and potential voids in the final component.

The CAMSIZER X2 utilizes Dynamic Image Analysis (DIA), which measures both the length and width of particles independently, providing a more accurate representation of particle shape and size. In contrast, traditional methods like laser diffraction only calculate one size parameter based on a spherical model, which can lead to misinterpretation of irregularly shaped particles.

The CAMSIZER X2 can analyze a variety of metal powders, including aluminum, cobalt, chromium, inconel, manganese, molybdenum, nickel, steel, titanium, tungsten, silver, gold, and their respective alloys.

Yes, by providing comprehensive analysis of particle size and shape, the CAMSIZER X2 ensures that only high-quality powders are used in the printing process. This consistency is vital for producing reliable and high-performance components in additive manufacturing.

The CAMSIZER X2 measures particle width, length, and equivalent circle diameter. This detailed analysis helps in understanding particle shape and size distribution, which is crucial for applications like additive manufacturing.

The CAMSIZER X2 can perform measurements on metal powders in less than 20 seconds per sample. This high throughput makes it suitable for rapid quality control and analysis in industrial applications.

The CAMSIZER X2 is capable of analyzing a variety of metal powders, including titanium and steel, among others. It is particularly effective for fine powders with a particle size down to 1 μm

Dynamic image analysis with the CAMSIZER X2 provides valuable insights into particle shape and size distribution, which are essential for optimizing raw and recycled materials in additive manufacturing. The ability to detect small amounts of oversized particles and deviations from desired shapes enhances the overall quality and performance of printed components.