ATO Lab Ultrasonic Atomizer
Quick production of high quality metal powders.
-
Technology:
Ultrasonic atomization
In stock
- Description
- Details
- Materials
- Documents
- Videos
- Review
Description
Make High-Quality Metal Powders in Your Laboratory
ATO Lab Plus allows you to produce metal powder yourself, giving full control over material quality and development cycles.
High powder sphericity and flowability
Narrow Particle Size Distribution (PSD)
Low oxygen content for stable AM performance
Suitable for reactive and non-reactive alloys
Proven Ultrasonic Atomization Technology
ATO Lab Plus uses ultrasonic atomization to break molten metal into fine droplets that solidify into near-perfect spherical particles in an inert gas atmosphere.
Ordered atomization process
PSD controlled by ultrasonic frequency
Excellent repeatability between batches
Minimal material waste
Compact, Self-Sufficient Lab System
Designed for real laboratory environments, ATO Lab Plus offers advanced powder production in a small, self-sufficient footprint.
Fits into limited lab spaces
No sophisticated infrastructure required
Low operating costs
Fast return on investment
ATO INSIDE
Modular Feeding & Melting Capabilities
ATO Lab Plus features a flexible modular architecture, allowing adaptation to different materials and feedstock forms.
Available feeding systems:
Wire Feeding System
Single Rod Feeding System
Multi Rod Feeding System
Revolver Rod Feeding System
Custom feeders on request
Optional melting modules:
TIG melting (standard)
Induction melting (optional)
Particle Size Control for Multiple Applications
By selecting the appropriate ultrasonic frequency module, users can tune PSD for different processes:
LPBF / SLM
DED / Laser cladding
Binder Jetting
Powder Metallurgy / MIM
HIP / SPS / PPS
One compact system — multiple powder applications.
Cost-Effective & Accessible Powder Production
Compared to traditional atomization systems, ATO Lab Plus is:
More resource-efficient
Faster to set up
Economical to operate
Affordable for labs, SMEs, and startups
A practical entry point into in-house metal powder production.
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
ato patents
Part of the ATO Metal Powder Production Suite – ATO PERIPHERALS
ATO Lab Plus integrates with the ATO Metal Powder Production Suite, enabling a complete workflow:
Ultrasonic atomization
Powder sieving
Ultrasonic cleaning
Powder handling and recycling
Frequently Asked Questions (FAQ
ATO Lab Plus is a compact ultrasonic metal powder atomizer designed for laboratory environments. It enables fast, in-house production of high-quality spherical metal powders with controlled particle size distribution, low oxygen content, and excellent repeatability.
ATO Lab Plus uses ultrasonic atomization, where molten metal is exposed to ultrasonic vibrations and broken into fine droplets that solidify into spherical powder particles inside an inert gas atmosphere.
Key benefits include high powder sphericity, narrow PSD, low oxygen content, minimal material waste, compact footprint, low operating costs, and full control over material development cycles.
Yes. ATO Lab Plus is specifically designed for real lab environments. It features a small, self-sufficient footprint, requires no sophisticated infrastructure, and fits easily into limited laboratory spaces.
Yes. ATO Lab Plus produces powders suitable for LPBF/SLM, DED/laser cladding, Binder Jetting, Powder Metallurgy, MIM, HIP, SPS, and PPS applications.
Particle size distribution is controlled by selecting the appropriate ultrasonic frequency module. Higher frequencies produce finer powders, while lower frequencies generate coarser particles.
ATO Lab Plus supports fine powders for LPBF/SLM, medium fractions for Binder Jetting and MIM, and coarser powders for DED, laser cladding, and powder metallurgy — all from one compact system.
ATO Lab Plus supports both reactive and non-reactive alloys, including aluminum alloys (AlSi7Mg, AlSi10Mg, Al-Mg), steels, and stainless steels such as SS304 and SS316L, as well as alloys like 42CrMo4, AMS5832, Fe 99.5%, FeMn, and PH177.
Yes. The system operates in an inert atmosphere and produces low-oxygen powders, making it suitable for reactive materials and sensitive AM alloys.
ATO Lab Plus produces near-perfect spherical metal powders with smooth surfaces, resulting in excellent flowability and consistent additive manufacturing performance.
Ultrasonic atomization provides an ordered, stable process with excellent repeatability between batches, enabling reliable powder quality for R&D and production trials.
Yes. ATO Lab Plus is ideal for small-batch and experimental powder production, allowing users to qualify materials without purchasing large quantities of commercial powder.
ATO Lab Plus supports multiple feeding options, including Wire Feeding, Single Rod Feeding, Multi Rod Feeding, Revolver Rod Feeding, and custom feeders upon request.
The standard configuration uses TIG melting, with induction melting available as an optional upgrade for specific materials and workflows.
Yes. ATO Lab Plus features a modular architecture that allows users to adapt feeding systems and melting modules based on material type and application requirements.
ATO Lab Plus is more resource-efficient, faster to set up, and significantly more economical to operate, making it an accessible entry point into in-house metal powder production for labs, SMEs, and startups.
Yes. The ultrasonic atomization process minimizes material loss, and in-house production reduces dependency on external suppliers and excess powder purchases.
ATO Lab Plus is used in additive manufacturing, materials research, academic laboratories, product development, and industrial R&D environments.
Yes. ATO Lab Plus is part of the ATO Metal Powder Production Suite and integrates with powder sieving, ultrasonic cleaning, powder handling, recycling modules, and induction melting systems.
Yes. ATO Lab Plus is part of the ATO Metal Powder Production Suite and integrates with powder sieving, ultrasonic cleaning, powder handling, recycling modules, and induction melting systems.
Yes. ATO Lab Plus is in stock and available for quotation.
You can request a quote directly from the product page. The Additive Plus team can also help configure ATO Lab Plus based on your materials, applications, and lab setup.
- 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 < 150 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
-
Aluminium
-
Copper
-
HEA alloys
-
Magnesium
-
Nickel
-
Reactive metals
-
Refactory metals
-
Stainless Steel
-
Titanium
Videos
