Made to order

$ATO Lab Ultrasonic Metal Powder Atomizer – Ti, Al, Refractory Alloys$

With every system

Install, commissioning and on-site operator training
Applications support — frequency-to-PSD mapping for your alloys

Atomizers, Reactive (ATO Lab), Ultrasonic Metal Atomizers · Ultrasonic atomization

ATO Lab Ultrasonic Metal Powder Atomizer – Ti, Al, Refractory Alloys

Make spherical metal powder in your own lab — 20–120 µm, oxygen below 10 ppm, from wire, rod or scrap, for reactive, refractory and standard alloys.

Particle size set by ultrasonic frequency: 20, 35 or 52 kHz
Titanium, aluminum, nickel, steels, refractory metals and HEAs
Installation, training and US service included · free powder samples
Lead time 8–12 weeks · 12-month warranty

Prices follow supplier cost and stock availability and are updated regularly. The price you see is today's price — once you order, it's held for 7 days.

Installation + training included Free powder samples

20–120 µm frequency-tuned PSD

3 modules ultrasonic frequency (20–52 kHz)

Inert Ar low-oxygen atmosphere

In-house we run this atomizer (ATO Lab)

What your process engineer actually checks

Powder quality we run ourselves

We operate ultrasonic atomization in-house through AO Metal / ATO Lab, so we know what 20–120 µm, low-oxygen, spherical powder has to look like to actually print. A paid trial atomization of your target alloy is available before you commit to a system.

An applications engineer on the line

Factory-trained support, not a remote ticket queue. We match the melting module, feeding system and ultrasonic frequency to your alloys and help map frequency-to-PSD.

20–120 µm

Particle size (PSD)

20/35/52 kHz

Ultrasonic frequency

Up to 0.3 L/h

System throughput

Inert argon

Atmosphere

600 kg

System weight

About this product

Price

Quoted to your configuration

The price depends on the melting module, the feeding system and the ultrasonic frequency modules your alloys need, and on the peripherals you add — chiller, ATO Sieve, ATO Clean, passivation. You receive a formal quotation on our letterhead with configuration, price, payment terms and lead time: the document your purchasing department asks for. Installation and on-site operator training are included in every quotation. Lead time 8–12 weeks.

What you configure

ATO Lab base unit — TIG melting, patented half-wave nanoalloy sonotrode, vacuum pump, argon recirculation, cyclone and ATO powder container
Ultrasonic frequency modules — 20, 35 or 52 kHz — to set the particle size
Feeding system: wire, single rod, multi rod, revolver rod or custom
Plasma melting or the Induction Melting System (IMS) for crucible and scrap feedstock
ATO Sieve, ATO Clean and the Passivation Module for print-ready powder
Installation and on-site operator training — included in every quotation

Next stepRequest a formal quotation

Free powder samples of standard alloys are available, so you can test ultrasonic powder on your own printer or analyzer before you decide. A paid trial atomization of your own alloy can be arranged.

20–120 µmSpherical powder, size set by the ultrasonic frequency module

< 10 ppm O₂In the process chamber during atomization, under argon

Up to 0.3 L/hSeveral hundred grams of powder per hour, depending on the alloy

Up to ~3100 °CMelting points from aluminum and magnesium to tungsten, niobium and tantalum

What the ATO Lab is

The ATO Lab is a lab-size ultrasonic metal powder atomizer made by 3D Lab in Warsaw, Poland — the current, next-generation version of 3D Lab’s lab atomizer. Feedstock — wire, rod or scrap — is melted by a TIG or plasma arc, or by induction, and forms a thin liquid film on the tip of a sonotrode. A piezoelectric transducer drives the sonotrode at ultrasonic frequency; the standing wave in the molten metal becomes unstable and ejects droplets of nearly equal size, which surface tension rounds into spheres while they fall through cooled argon. A cyclone separates the powder into a sealed ATO powder container that keeps the argon shield.

Because droplet size follows the frequency, the particle size distribution is narrow and repeatable: higher frequency gives finer powder, lower frequency coarser. There is no crucible or nozzle in the standard arc-melting route, the chamber runs at about 50 mbar with oxygen below 10 ppm, and batches are sized to the experiment — so a lab can design an alloy, atomize it the same week and qualify it without buying a large minimum order of catalog powder. The method is patent-protected: 3D Lab holds granted patents for ultrasonic atomization in the United States (US 12,090,554 B), Poland, China, Japan, South Korea and India. Published installations include INFN Gran Sasso National Laboratory and REMET.

Specifications

Manufacturer	3D Lab, Warsaw, Poland
Process	Ultrasonic atomization, patented half-wave nanoalloy sonotrode
Particle size (PSD)	20–120 µm, depends on the frequency module
Ultrasonic frequency	20 / 35 / 52 kHz (upgradable)
Throughput	up to 0.3 L/h — several hundred grams per hour
Oxygen level	below 10 ppm O₂ in the chamber during atomization
Chamber pressure	approx. 50 mbar during atomization
Melting	TIG (standard) · plasma · induction (IMS module)
Melting range	approx. 700–800 °C up to about 3100 °C
Input material	wire, rods, scrap, irregular pieces
Inert gas flushing	vacuum pump; atmosphere ready in under 15 min
Powder collection	cyclone into the ATO powder container, under argon
Cooling	liquid, external chiller
Control	touchscreen; every run logged; remote control module available
Safety	cooling-water monitoring, automatic gas shut-off valves, emergency stops; feedstock-end detection stops the process
Certification	CE Declaration of Conformity
Dimensions (H × W × D)	1997 × 813 × 1626 mm (78.6 × 32.0 × 64.0 in)
Weight	confirmed in the formal quotation
Warranty	12 months
Installation and training	on site, included in every quotation
Lead time	8–12 weeks

Download: the ATO Lab brochure and the ATO devices brochure are in the Downloads tab above.

Alloys already atomized on ATO

3D Lab has developed stable procedures for these alloys on its ultrasonic atomizers. Other meltable and weldable compositions can be atomized after parameter development.

Steels	SS316L, SS304, 42CrMo4, AMS5832, PH17-7, Fe 99.5%, FeMn
Titanium	Ti Gr.1, Gr.2, Gr.5 (Ti6Al4V), Ti5Al2.5Sn, TiAl, TiMoSi
Nickel	Inconel 625, Inconel 718, Ni 99%, NiTi, NiTiHf
Aluminum	AlSi10Mg, Al7075, Al4047, Al5183, AlMg, AlMgSc, Al 99.99%
Magnesium	AZ31, WE43, WE54, MgAl9Zn1, ZX00
Copper	CuCrZr, CuSn, CuNi3Si, CuAlNiFe, CuMnAl
Refractory	Nb 99%, Ta 99%, W90Ni7Fe3, MoSi₂
High-entropy	AlCoCrFeNi, CoCrFeMo, FeNiCrMo, NiCrFe, FeNiAlCr
Precious	Au 9 ct, 18 ct and 99.99%, Ag 99%, Pt alloys, Ir 99%
Special	Zr-based bulk metallic glasses (small quantities), MoS₂

Which frequency for which process: finer powder from higher frequencies for LPBF and SLM, medium fractions for binder jetting and MIM, coarser powder from lower frequencies for DED, laser cladding and conventional powder metallurgy.

A short video of the atomizer at work is in the Video tab above.

Powder made on ATO

Spherical powder from alloys 3D Lab has atomized on the ATO Lab — titanium alloys, refractory metals, nickel superalloys and precious metals. Images: 3D Lab material reports and case studies.

TiMo powder atomized on the ATO Lab with TIG melting — TiMo — ATO Lab, TIG

TiZrNb powder atomized on the ATO Lab with TIG melting — TiZrNb — ATO Lab, TIG

Niobium powder atomized from rods on the ATO Lab — Niobium from rods — ATO Lab, TIG

Inconel 718 powder atomized on the ATO Lab with plasma melting — Inconel 718 — ATO Lab, plasma

Platinum-copper PtCu powder atomized on the ATO Lab — PtCu (platinum-copper) — ATO Lab, TIG

SEM image of a spherical metal powder particle made on an ATO atomizer at FZU — Single particle, SEM — FZU case study

Who already runs ATO — published case studies

Three users have published how they work with 3D Lab’s ultrasonic atomizers (3D Lab case studies).

FZU — Institute of Physics, Czech Academy of Sciences	Bought an ATO Lab Plus to connect alloy research with part production in-house: alloy design, powder, print-parameter calibration and final parts. Projects run on titanium, zinc, aluminum and high-entropy alloys, with significant progress on beta-titanium alloys.
REMET S.A., Poland	A manufacturer of welded structures for the oil & gas and energy sectors. It installed the ATO Lab to make powder in-house from wire and scrap, including compositions not sold commercially (trials included Al-Sc), and to recycle supports and scrap. REMET rates the sphericity of its ATO powder above commercial powders from other suppliers.
AZTERLAN, Spain	A metallurgy research center. It uses ATO to make ad-hoc powders for its patented surface-conditioning method for iron castings, which are then coated by laser metal deposition.

Peer-reviewed research on ultrasonic atomization

Grzelak et al., Materials 15 (2022) 4938	Military University of Technology and 3D Lab compared LPBF parts from ultrasonic-atomized and plasma-arc gas-atomized 316L: both routes can deliver material of similar properties.
Bałasz, Bielecki, Gulbiński, Słoboda, JAMME 116(1) (2023)	Ultrasonic versus gas atomization: the ultrasonic powder had a finer average particle size, a narrower size distribution and higher sphericity.
Hinrichs et al. (KIT, GfE), Metals 11 (2021) 1723	Mo-20Si-52.8Ti refractory alloy powder made by ultrasonic atomization met the needs of alloy development for powder bed fusion.
Monti et al. (Inspire AG, ETH Zürich), Materials & Design 229 (2023) 111907	A new Al-Cu alloy for LPBF, designed against hot cracking, with its powder developed via ultrasonic atomization.

Three ways to melt the feedstock

TIG — standardAn electric arc melts wire or rod directly on the sonotrode tip. No crucible, so nothing touches the melt but the sonotrode — the default route for steels, titanium, nickel and refractory alloys.

PlasmaA plasma arc for alloys that need more heat input. Fitted in place of the TIG torch on configurations that call for it.

Induction — IMSAn optional, easy-to-swap module that melts in a crucible or from a rod. It takes irregular pieces and scrap, and limits evaporation of low-melting elements in aluminum, magnesium or gold alloys. It can be added later to an installed ATO Lab.

Which feedstock you can use

The ATO Lab takes feedstock in almost any form; the feeding system decides which. Custom feeders are made on request.

Feeding option	Feedstock	Diameter	Length
Wire Feeding System (WFS)	Standard market wire	0.8–2.4 mm	Continuous
Single Rod Feeding System (SRFS)	Rod or bar, incl. freshly cast, porous or non-round	2–10 mm	Up to 110 mm
Multi Rod Feeding System (MRFS)	Straight rods of constant diameter	4–10 mm	Up to 1,200 mm per rod, several rods per run
Revolver Rod Feeding System	Up to 10 rods in a revolver cylinder, sized to match ATO Cast rods	4–10 mm	Short rods (see note)
Induction Melting System (IMS) with crucible	Irregular pieces and scrap	Depends on configuration	Depends on configuration

Rods for the multi rod and revolver feeders must be straight with a constant diameter; machined and rolled rods both work, sanding is usually not needed. 3D Lab lists revolver rods as up to 110 mm on its technology page and up to 120 mm (ATO Cast rod size) on the module page — the quotation confirms the figure for your configuration.

Infrastructure and installation requirements

The ATO Lab installs in a standard materials lab. This is what facilities and procurement need to plan the installation:

Footprint (W × D)	813 × 1626 mm (32.0 × 64.0 in); height 1997 mm (78.6 in)
Weight	confirmed in the formal quotation
Electrical supply	3-phase, 400–440 V, 50/60 Hz (±10%), L1/L2/L3/N/PE; configured to the local standard of the destination country
Installed power	12–20 kW depending on configuration; average draw about 4 kW, peaks up to 7.9 kW
Process gas	Argon, purity 5.0 (99.999%) or higher recommended; typical use 15–25 L/min, about 90% of the argon is recovered and recirculated
Compressed air	Required (compressor or shop air)
Cooling	External liquid chiller; water-jacketed stainless steel process chamber
Peripherals	Ultrasonic cleaner (ATO Clean) and sieving unit (ATO Sieve); ventilation may be recommended depending on the room
Noise	max. 72.9 dB
Room	A standard materials lab, R&D facility or SME workshop — no atomization tower, no dedicated powder plant

Where the ATO Lab stops — and what to take instead

The ATO Lab is a research and small-batch machine: up to about 0.3 L of powder per hour, roughly 0.5 kg/h for Ti6Al4V and 1 kg/h for Inconel 718 or 316 from 1–1.6 mm wire. If you need tonnes of one standard alloy, buying gas-atomized powder remains cheaper. Its range is 20–120 µm; for powders targeting about 25 µm ask about 3D Lab’s Ultra Frequency System module. If you want AI-guided parameter setup, two camera views of the process and one operator supervising several atomizers, look at the ATO Sparq. For gold, silver and platinum, where every gram of loss counts, the ATO Noble adds Zero Loss recovery. Raw powder still needs sieving and, for reactive metals, passivation: plan for ATO Sieve, ATO Clean and the Passivation Module. And if you need a few kilograms of one alloy rather than a machine, order custom alloy powder instead.

Make your own powder, measure it, print it

We supply the ATO Lab, the Microtrac CAMSIZER X2+ particle size and shape analyzer and our own AO Metal LPBF printers. Together they close the loop inside your own laboratory: atomize an alloy, check its size distribution and sphericity, print it, adjust the frequency or the chemistry, repeat. Upstream, ATO Cast casts your alloy into rods and ATO Wipe cleans the feedstock; downstream, ATO Pure cleans and dries the powder. The atomizer, analyzer and printer are also offered together as the R&D Bundle with the AO Metal A50.

Material reports from 3D Lab

3D Lab has documented atomization results for 22 alloys — Ti6Al4V, TiMo, TiZrNb, niobium, CoCr, Inconel 625 and 718, Haynes 282, 316L and 303 steel, aluminum and copper alloys, gold, PtCu, and the magnesium alloys WE43 and ZX00: particle size distribution (D10/D50/D90), circularity and micrographs at ×100 and ×1000.

Request material reports →

See it running in California

Before you commit, you can see an ATO atomizer running at UC Irvine (UCI). Tell us which alloys you work with and we arrange the visit; it is a direct way to judge the process, the footprint and the powder with your own eyes before you order an ATO Lab.

Book a visit at UC Irvine

In pictures

3D Lab ATO Lab ultrasonic atomizer – internal melt and sonotrode chamber — Inside ATO Lab: melt source, half-wave nanoalloy sonotrode, and inert-atmosphere atomization chamber.

Spherical aluminium metal powder produced on the ATO Lab ultrasonic atomizer — Representative spherical aluminium powder atomized on an ATO ultrasonic system.

ATO Lab ultrasonic atomizer footprint and lab-scale dimensions — ATO Lab — lab-scale footprint.

Availability, payment and delivery

Built to orderEach ATO Lab is configured with the melting, feeding and frequency modules your alloys need. Lead time is 8–12 weeks after a confirmed order; the quotation states the date in writing.

How you payAsk for a formal quotation on our letterhead with configuration, price, payment terms and lead time, and pay against an invoice. We are registered in SAM.gov as a small business, so federal and university purchasing works the usual way.

What arrivesThe ATO Lab with the frequency, melting and feeding modules you ordered and the ATO powder container. Installation and on-site operator training are included in every quotation and carried out by US service engineers; 3D Lab provides a parameter database for common materials.

Why buy it through Additive Plus

Authorized US distributorAdditive Plus is the authorized US distributor of ATO by 3D Lab. Quotation, order, delivery and support are handled by one team in California

US service engineers and local warrantyInstalled and your operators trained on site — part of every quotation. 12-month warranty serviced in the US

Free samples and trial atomizationFree powder samples of standard alloys, and a paid trial atomization of your own alloy, so you decide with powder in hand

What usually stops people — and the honest answer

“We do not have a powder facility.”You do not need one. The ATO Lab stands on 813 × 1626 mm of floor and runs on three-phase power, argon, compressed air and a chiller — utilities a materials lab already has or can add. The infrastructure table above is what your facilities team plans against.

“Ultrasonic powder is unproven for our printer.”Ask for a free sample of a standard alloy and run it on your own machine, or see an ATO atomizer working at UC Irvine. For your own composition, a paid trial atomization gives you powder before you commit.

“Reactive alloys are a safety risk.”The chamber is evacuated and filled with argon, oxygen stays below 10 ppm during atomization, and powder is collected under argon in a sealed container. The platform is CE-marked, has ATEX-oriented design features, and the Passivation Module treats reactive powder before it meets air.

“We will spend months finding parameters.”3D Lab supplies a parameter database for common materials and can develop parameters for a specific alloy as a paid project. The software logs every run, so a good batch can be repeated.

“Switching alloys will contaminate the powder.”Changeover is a single-operator job: ATO Clean cleans all powder-contact parts in one cycle of under 30 minutes, which keeps cross-contamination between alloy groups down.

Ready when you are

Request a formal quotation

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)	20-120 micrometres
Powder collecting system	Cyclone
Protective atmosphere preparation time	<15 min.
Input material	Irregular, Rods, Scrap, Wire
Certification	CE
Ultrasonic frequency	20, 35, 52
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

ATO Technology devices brochure

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ATO Lab brochure

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Product videos

What our customers say

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Common questions

Don't see yours? Email [email protected] — NDA on request, typical reply within 4 hours.

What is the ATO Lab?

The ATO Lab is a lab-size ultrasonic metal powder atomizer made by 3D Lab in Poland. It turns wire, rod or scrap into spherical metal powder of 20–120 µm with a narrow particle size distribution and low oxygen content, so a lab can produce and qualify its own powder instead of ordering it. It is the current, next-generation version of 3D Lab's lab atomizer.

What technology does the ATO Lab use?

Ultrasonic atomization. The feedstock is melted by a TIG or plasma arc, or by induction, on the tip of a sonotrode driven by a piezoelectric transducer. The ultrasonic standing wave in the molten metal ejects droplets that solidify into spherical particles in cooled argon and are collected by a cyclone.

What are the main benefits of the ATO Lab?

High sphericity and flowability, a narrow particle size distribution set by frequency, oxygen below 10 ppm in the chamber, small batches with little material waste, a lab-size footprint without an atomization tower, and full control over alloy development.

Is the ATO Lab suitable for laboratory use?

Yes. It is designed for standard materials labs, R&D facilities and small companies. It measures 1997 × 813 × 1626 mm and needs three-phase power, argon, compressed air and a chiller — no dedicated powder plant.

Can the ATO Lab produce powder for metal 3D printing?

Yes. Its powder is used for LPBF/SLM, DED and laser cladding, binder jetting, MIM, conventional powder metallurgy, HIP and other powder processes. The frequency module is chosen to suit the fraction each process needs.

How is particle size controlled?

By the ultrasonic frequency module. Higher frequencies produce finer powder, lower frequencies coarser powder. To change the distribution you physically exchange the module and the software adjusts to it. Material, process parameters and melting route also influence the result.

What particle size ranges are supported?

The ATO Lab produces 20–120 µm. Fine fractions suit LPBF/SLM, medium fractions binder jetting and MIM, coarser fractions DED, laser cladding and powder metallurgy — all from one system. For a target of about 25 µm, 3D Lab offers the Ultra Frequency System module.

What materials can be atomized with the ATO Lab?

Reactive and non-reactive alloys: steels and stainless steels (SS304, SS316L, 42CrMo4, AMS5832, PH17-7, Fe 99.5%, FeMn), titanium alloys (Gr.1, Gr.2, Ti6Al4V, Ti5Al2.5Sn, TiAl), nickel alloys (Inconel 625 and 718, NiTi, NiTiHf), aluminum alloys (AlSi10Mg, Al7075, Al4047, AlMg, AlMgSc), magnesium, copper, refractory metals (Nb, Ta, W90Ni7Fe3, MoSi2), high-entropy alloys and Zr-based bulk metallic glasses in small quantities.

Is the ATO Lab suitable for reactive alloys?

Yes. The chamber is evacuated by a vacuum pump and filled with argon, oxygen is kept below 10 ppm during atomization, and the powder is collected under argon. That is why titanium, aluminum, zirconium-based and other reactive alloys can be atomized. For reactive powders, add the Passivation Module before the powder is exposed to air.

How spherical is the powder produced?

Ultrasonic atomization produces highly spherical particles with few satellites and good flowability. For aluminum, 3D Lab reports a sphericity of 0.93 at an equivalent diameter of about 50 µm. Measure your own batches with a particle shape analyzer such as the CAMSIZER X2+.

How repeatable are the results?

Ultrasonic atomization is an ordered process: droplet size follows the frequency, so batches repeat. The software records the key parameters of every run, which lets you compare runs and reproduce a good one.

Does the ATO Lab support small batch production?

Yes. Small batches are what it is built for: you can atomize just enough of an experimental alloy to qualify it instead of buying large quantities of commercial powder.

What feeding systems are available?

Wire Feeding System (0.8–2.4 mm wire, continuous), Single Rod Feeding System (2–10 mm rods up to 110 mm), Multi Rod Feeding System (4–10 mm rods up to 1,200 mm), Revolver Rod Feeding System (up to 10 short rods), a crucible with the Induction Melting System for irregular pieces and scrap, and custom feeders on request.

What melting options are offered?

TIG melting is standard. Plasma melting and the Induction Melting System (IMS) are available as modules for specific materials and feedstock forms.

Is the ATO Lab modular?

Yes. Feeding systems, melting modules and frequency modules are exchangeable, so the same atomizer can be adapted to different materials and feedstock forms, and extended later — the IMS, for example, can be added to an installed system.

How cost-effective is the ATO Lab compared to traditional atomizers?

For research and small batches it is far less resource-hungry than gas atomization: no tower, typical argon use of 15–25 L/min with about 90% recovered, and average power of about 4 kW. For tonnage production of one standard alloy, gas atomization remains the cheaper route per kilogram.

Does the ATO Lab help reduce material waste?

Yes. You atomize only what you need, scrap and printing leftovers can be fed back as feedstock, and in-house production removes excess powder purchases.

What industries use the ATO Lab?

Additive manufacturing, aerospace, automotive, medical devices, energy, defense, tooling, academic and national laboratories, and industrial R&D. Published users include INFN Gran Sasso National Laboratory and REMET.

Can the ATO Lab integrate with other ATO systems?

Yes. It is part of the ATO Metal Powder Production Suite: ATO Cast for casting feedstock rods, ATO Wipe for feedstock cleaning, ATO Sieve for sieving under argon, ATO Pure for powder cleaning and drying, ATO Clean for cleaning atomizer parts, plus feeding, induction melting and passivation modules. The ATO powder container moves powder between them under argon.

Does the ATO Lab require complex infrastructure?

No. It needs a 3-phase 400–440 V, 50/60 Hz supply (12–20 kW installed, about 4 kW average), argon of 5.0 purity, compressed air, an external liquid chiller, and floor space for a unit 1997 mm high with an 813 × 1626 mm footprint. The atmosphere is ready in under 15 minutes. No tower or special construction is required.

Is the ATO Lab currently available?

Yes. Each ATO Lab is built to order with the modules you choose. Lead time is 8–12 weeks after a confirmed order, and the formal quotation states the date.

How can I request pricing or technical guidance?

Use the Request a formal quotation button on this page. You receive a quotation on our letterhead with configuration, price, payment terms and lead time; an applications engineer can help choose the melting, feeding and frequency modules for your alloys first.

Can the system process scrap or recycled metal?

Yes. Depending on the feeding configuration, the ATO Lab processes rods, wire and clean scrap, including 3D printing leftovers; irregular scrap is melted in a crucible with the Induction Melting System. The cleaner the feedstock, the cleaner the powder.

What throughput does the ATO Lab offer?

Up to about 0.3 L of powder per hour, depending on the material. 3D Lab gives typical figures from 1–1.6 mm wire: Ti6Al4V about 0.5 kg/h, Inconel 718 and AISI 316 about 1.0 kg/h, platinum about 0.8 kg/h; aluminum about 0.6 kg/h and magnesium about 0.3 kg/h with the IMS.

What ultrasonic frequencies are available?

Frequency modules of 20, 35 and 52 kHz are available for the ATO Lab, and the system is upgradable. The quotation states which modules are included in your configuration.

Can I customize the melting system?

Yes. TIG is standard; plasma and induction (IMS) are available depending on the materials. Induction can reduce thermal exposure and evaporation of volatile alloying elements.

Which organizations use the ATO Lab?

Universities, national and research laboratories, aerospace and defense organizations, medical device companies, advanced materials labs and additive manufacturing service providers.

Is the ATO Lab suitable for alloy development?

Yes. It is built as a research platform with full control over process parameters, so you can design an alloy, cast it into rods, atomize it and test it in a short cycle without relying on outside powder suppliers.

Does Additive Plus offer trial atomization?

Yes. A paid trial atomization of your own alloy can be arranged, so you can evaluate powder quality and particle size distribution before you buy. Free powder samples of standard alloys are also available.

How much does the ATO Lab cost?

The ATO Lab is quoted to your configuration: the melting module, feeding system, frequency modules and peripherals such as the chiller, ATO Sieve and ATO Clean all change the price. Request a formal quotation and you receive configuration, price, payment terms and lead time on our letterhead. Installation and on-site operator training are included in every quotation.

Can I get a free powder sample?

Yes. Free powder samples of standard alloys are available, so you can check ultrasonic powder on your own printer or analyzer. For your own composition, a paid trial atomization can be arranged.

What are the lead time and warranty?

Lead time is 8–12 weeks after a confirmed order. The warranty is 12 months, with US service engineers and local warranty support.

Can I see an ATO atomizer running before I buy?

Yes. We invite customers to see an ATO atomizer running in California, at UC Irvine. Book your visit on our visit page: additiveplus.com/ato-visit/.

Which alloys has ATO technology already atomized?

Steels, titanium, nickel, aluminum, magnesium, copper, refractory, precious and high-entropy alloys — more than fifty named alloys, from SS316L and Ti6Al4V to Inconel 718, AlSi10Mg, CuCrZr, Nb, Ta and AlCoCrFeNi. Other meltable and weldable alloys can be atomized after parameter development.

What oxygen level does the ATO Lab reach?

During atomization the process chamber is kept below 10 ppm O2 at about 50 mbar. The vacuum pump and argon management prepare the atmosphere in under 15 minutes.

Does atomization change the chemistry of my alloy?

The powder chemistry is typically very close to the feedstock. As with any melting process, limited evaporation of volatile elements such as manganese can occur; it is minimized by process optimization, and induction melting can reduce it further.

What melting temperatures can the ATO Lab handle?

From about 700–800 °C up to about 3100 °C, depending on the configuration and melting route — aluminum and magnesium at one end, tungsten, niobium and tantalum at the other.

How long does it take to change from one alloy to another?

Changeover is done by one operator. ATO Clean cleans all parts that touch powder in a single cycle of under 30 minutes, which shortens preparation and limits cross-contamination.

What are the electrical requirements?

A 3-phase supply of 400–440 V, 50/60 Hz (±10%) with L1, L2, L3, N and PE. Installed power is 12–20 kW depending on configuration; average consumption is about 4 kW, with peaks up to 7.9 kW. Systems are configured to the electrical standard of the destination country.

How much argon does the ATO Lab use?

Typically 15–25 L/min during atomization. About 90% of the argon is recovered, purified and returned to the process. Argon of 5.0 purity (99.999%) or higher is recommended.

Is the ATO Lab certified?

It is supplied with a CE Declaration of Conformity and includes design features aligned with ATEX-related requirements for metal powder processing. Documentation is provided according to the regulations of the destination country.

Can the ATO Lab be operated remotely?

Yes, with the ATO Remote Control module: process data, machine status and atomization runs can be monitored and supervised over a secure network connection.

Is the ATO Lab process patented?

Yes. 3D Lab holds granted patents for ultrasonic atomization of metals in the United States (US 12,090,554 B), Poland, China, Japan, South Korea and India, with further applications pending.

What is the difference between the ATO Lab, ATO Sparq and ATO Noble?

All three use the same ultrasonic platform and 20–120 µm range. The ATO Lab gives hands-on control of every parameter. The ATO Sparq adds AI-guided parameter setup, two camera views and supervision of several atomizers by one operator. The ATO Noble is adapted for gold, silver, platinum and other precious metals, with Zero Loss recovery.

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ATO Lab Ultrasonic Metal Powder Atomizer – Ti, Al, Refractory Alloys

What your process engineer actually checks

Powder quality we run ourselves

An applications engineer on the line

What the ATO Lab is

Specifications

Alloys already atomized on ATO

Powder made on ATO

Who already runs ATO — published case studies

Peer-reviewed research on ultrasonic atomization

Three ways to melt the feedstock

Which feedstock you can use

Infrastructure and installation requirements

Where the ATO Lab stops — and what to take instead

Make your own powder, measure it, print it

Material reports from 3D Lab

See it running in California

In pictures

Availability, payment and delivery

Why buy it through Additive Plus

What usually stops people — and the honest answer

Ready when you are

ATO Technology devices brochure

ATO Lab brochure

Product videos

Send feedstock We atomizePowder + full data

Other products teams run alongside ATO Lab Ultrasonic Metal Powder Atomizer – Ti, Al, Refractory Alloys

What our customers say

Common questions

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