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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 Plus Ultrasonic Metal Powder Atomizer – Reactive & Refractory Alloys | 20–120 µm
Benchtop ultrasonic atomizer for reactive and refractory alloys — 20–120 µm frequency-tuned powder, up to 0.3 L/h, atomized in an inert argon atmosphere for low-oxygen AM feedstock.
- ✓ Produce your own Ti, Al, Zr, NiTi and HEA powder in-house
- ✓ Narrow PSD set by ultrasonic frequency · spherical, high-flow particles
- ✓ Lab-scale footprint on 400 V 3-phase — no dedicated powder facility
- ✓ Lead time: configured to order — request current lead time
Price held 7 days after order.
Install + training included
Tailored service plan
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. Sub-24h reply, NDA standard.
20–120 µm
Particle size (PSD)
20/35/52/72 kHz
Ultrasonic frequency
Up to 0.3 L/h
System throughput
Inert argon
Atmosphere
600 kg
System weight
About this product
ATO Lab Plus is a benchtop ultrasonic atomizer that turns solid metal feedstock — rod, wire or scrap — into fine, spherical metal powder for 3D printing and powder metallurgy. It gives a lab full control over alloy and batch: a 20–120 µm particle size distribution set by ultrasonic frequency, low oxygen content, and an inert argon atmosphere suited to reactive and refractory metals. Its lab-scale footprint fits a standard materials lab, so R&D teams make and qualify their own powder instead of waiting on an outside supplier.
Why R&D teams choose ATO Lab Plus
Spec-backed reasons a materials engineer runs this over an external powder order.
Ordered, frequency-tuned particle size
Ultrasonic atomization gives a narrow 20–120 µm distribution. Particle size is set by the frequency module (20 / 35 / 52 / 72 kHz) — not by chance turbulence — so batches repeat.
Low-oxygen, spherical powder
Atomization in an inert argon atmosphere holds oxygen pickup low (delta <150 ppm) and yields near-spherical particles with high flowability — the powder quality LPBF and DED depend on.
Reactive & refractory alloys
Titanium, aluminium, zirconium, NiTi / TiAl / NiAl intermetallics, high-entropy alloys and refractory metals — from rod, wire or scrap. Qualify compositions no catalog powder covers.
Lab-scale footprint
1997 × 813 × 1626 mm / 78.6 × 32.0 × 64.0 in, 600 kg, on a 400 V 3-phase / 20 kVA supply. No dedicated powder plant and no industrial gas-atomization tower — it runs in a normal materials lab.
From your lab to first powder
How Additive Plus configures, installs and dials in ATO Lab Plus around your alloys.
Step 01
Configure to your alloys
We spec the melting module — TIG standard, induction optional — feeding system (wire, single/multi-rod, scrap) and frequency modules around the materials you actually run.
Step 02
Install & commission
Delivered with chiller, argon supply and cyclone collection defined. We install, run first powder, and train your team on the atomization and inert-atmosphere workflow.
Step 03
Dial in repeatable batches
We map frequency-to-particle-size for your alloys and integrate ATO Sieve, ATO Clean and passivation so the powder is print-ready, not just atomized.
Atomization Technology & Powder Quality
ATO Lab Plus breaks molten metal into fine droplets with a half-wave nanoalloy sonotrode, solidifying them into spherical particles under an argon atmosphere. Particle size is selected through the ultrasonic frequency, giving reproducible fractions for different downstream processes.
The atomization method is patent-protected. 3D Lab holds granted patents for producing spherical metal powder by ultrasonic atomization in the United States (US 12,090,554 B), Poland, China, Japan, South Korea and India, with further sonotrode and powder-evacuation patents pending — so this is a protected process, not a generic ultrasonic rig.
| Parameter | ATO Lab Plus |
|---|---|
| Particle size (PSD) | 20–120 µm, frequency-selected |
| Ultrasonic frequency modules | 20 / 35 / 52 / 72 kHz |
| Oxygen pickup | Low-oxygen inert argon process (delta <150 ppm) |
| System throughput | Up to 0.3 L/h (several hundred grams per hour) |
| Melting method | TIG (standard) · Induction (optional) |
| Input material | Irregular stock · rods · wire · scrap |
| Powder collection | Cyclone separator |
| Cooling | Liquid, external chiller |
See the Specifications tab for the full parameter set, including power, atmosphere prep time and system dimensions.
Processable Materials
ATO Lab Plus is built for the alloys that are hardest to source as ready powder — reactive and refractory metals atomized in a protected atmosphere.
- Titanium and Ti alloys, TiAl / NiTi / NiAl intermetallics
- Aluminium and Al alloys (AlSi7Mg, AlSi10Mg, Al-Mg)
- Nickel, copper and magnesium alloys
- Steels and stainless steels (SS304, SS316L, 42CrMo4, PH17-7)
- Zirconium-based bulk metallic glass and refractory metals
- High-entropy alloys (HEAs) and custom experimental compositions
Infrastructure & Installation Requirements
ATO Lab Plus installs in a standard materials lab — no dedicated powder facility. This is what facilities and procurement need to plan the install.
| Requirement | ATO Lab Plus |
|---|---|
| Footprint (W × D × H) | 1997 × 813 × 1626 mm / 78.6 × 32.0 × 64.0 in |
| Weight | 600 kg / 1,323 lb |
| Power supply | 400 V 3-phase, up to 20 kVA |
| Protective atmosphere | Argon; atmosphere prep in under 5 minutes |
| Cooling | External liquid chiller (supplied) |
| Powder handling | Cyclone collection; pair with ATO Sieve / ATO Clean for print-ready powder |
Typical Applications
LPBF / SLM R&D
Fine fractions for laser powder-bed alloy development
DED & laser cladding
Coarser, flowable powder for directed energy deposition
Binder jetting & MIM
Medium fractions for binder jetting and metal injection molding
Alloy qualification
Small-batch powder to test new compositions before scaling
Academic & materials research
University and institute powder-metallurgy programs
Reactive-metal powder
In-house Ti, Zr and refractory powder without an outside vendor
Not sure ATO Lab Plus is the right platform?
Higher throughputATO SparqView atomizer →
Precious metalsATO NobleView atomizer →
Full R&D cellAO Metal + ATO Lab Plus BundleView bundle →
Precious metalsATO NobleView atomizer →
Full R&D cellAO Metal + ATO Lab Plus BundleView bundle →
Tell us your target alloys, particle size and batch size — a materials engineer will confirm the melting module, feeding system and frequency configuration that fit, or point you to the right platform. Sub-4h reply, NDA standard.
Why Source ATO Lab Plus Through Additive Plus
- We run ultrasonic atomization in-house through AO Metal / ATO Lab — this is equipment we operate, not just resell.
- Applications engineering to match melting module, feeding system and frequency to your alloys before you commit.
- Full powder chain under one partner: atomizer, sieving (ATO Sieve), cleaning (ATO Clean), passivation and characterization.
- Install, commissioning and operator training included; sub-24h engineer response, NDA standard.
- 15,000+ teams supported across 23 countries.
| 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, 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 |
Product videos
Not ready to buy? We'll atomize your alloy
Send feedstock We atomizePowder + full data
Send us your target alloy and our in-house ATO Lab and AO Metal cell runs a paid trial atomization — spherical powder plus PSD, chemistry and flow data — so you qualify the process before you commit to a system.
Other products teams run alongside ATO Lab Plus Ultrasonic Metal Powder Atomizer – Reactive & Refractory Alloys | 20–120 µm
Atomizers · Ultrasonic Sieving
ATO Sieve Ultrasonic Powder Sieving Station – Inert Argon Atmosphere | 3D Lab
The ATO Sieve is an ultrasonic powder sieving station that screens reactive and non-reactive metal AM powder inside an inert argon atmosphere — the same ATO container transfers powder straight from an ATO atomizer, so it never sees oxygen.
- ✓ High-frequency ultrasonic vibration — prevents mesh clogging, keeps throughput high
- ✓ Sieves under inert argon; optional oxygen sensor for reactive metals (Ti, Al, Zr)
- ✓ Direct ATO-container transfer from ATO Lab Plus / ATO Sparq — no air exposure
- ✓ Various screens, optional mesh sizes — configured to your target cut
- ✓ Lead time: configured to order — request current lead time
On backorder
· Configured to order — request lead time
Bundle · Ultrasonic atomization, Metal LPBF
AO Metal A100 + ATO Noble + CAMSIZER X2: Jewelry Bundle
On backorder
· Configured to order — request lead time
Atomizers · Ultrasonic atomization
ATO Noble Ultrasonic Precious Metal Powder Atomizer – Gold, Silver & Platinum | Zero-Loss Recovery
ATO Noble is an ultrasonic atomizer built for precious metals — it turns gold, silver, platinum and palladium feedstock into fine, spherical powder with Zero Loss recovery, so almost none of the high-value metal is lost. TIG melting under an inert argon atmosphere (oxygen below 0.1%) keeps chemistry and karat unchanged through atomization.
- ✓ Purpose-built for gold (9–24ct), silver, platinum, palladium and iridium
- ✓ Zero Loss Technology — closed-loop gas and filtration recover unused metal
- ✓ Spherical, high-flow powder · particle size tuned by ultrasonic frequency
- ✓ Lead time: configured to order — request current lead time
Prints Ag, Au 18ct, Au 99,99%, Au 9ct, Ir 99%, Precious metals, Pt
On backorder
· Configured to order — request lead time
Atomizers
ATO Wire Feeding System
The ATO Wire Feeding System feeds wire feedstock into an ATO ultrasonic atomizer in a continuous, automated process — for reactive and non-reactive alloys, using standard welding-market wire.
- ✓ Continuous, automated wire feed for stable powder output
- ✓ Long-spool compatibility — fewer changes, higher uptime
- ✓ Accepts standard welding-market wire — no feedstock lock-in
- ✓ Lead time: configured to order — request current lead time
On backorder
· Configured to order — request lead time
Atomizers
ATO Single Rod Feeding System
The ATO Single Rod Feeding System feeds rod feedstock — 1 to 10 mm diameter, up to 110 mm long, including cast rods — directly into an ATO ultrasonic atomizer.
- ✓ Atomizes rods 1–10 mm diameter (best on 4–6 mm), up to 110 mm long
- ✓ Works with cast rods — atomize as-cast alloys directly
- ✓ Upgradeable to a Custom Shape Feeder for non-standard feedstock
- ✓ Lead time: configured to order — request current lead time
On backorder
· Configured to order — request lead time
Atomizers
ATO Induction Melting System for Ultrasonic Atomization
The ATO Induction Melting System (IMS) is an optional module designed to atomize materials and minimize evaporation of low melting point elements.
On backorder
· Configured to order — request lead time
Atomizers · Ultrasonic atomization
ATO Wipe | Ultrasonic Feedstock Cleaning System for Metal Powder Production
ATO Wipe is an ultrasonic wire-and-rod cleaning station that prepares feedstock for ultrasonic atomization — stripping oils, oxides and residues before the metal reaches the melt.
- ✓ Ultrasonic + mechanical brushing for deep surface decontamination
- ✓ Wire and rod compatible · automatic and manual modes
- ✓ Native to the ATO suite — feeds ATO Lab Plus, ATO Sparq and rod feeders
- ✓ Lead time: configured to order — request current lead time
On backorder
· Configured to order — request lead time
Bundle · Ultrasonic atomization, Metal LPBF
AO Metal A50 + ATO Lab Plus + CAMSIZER X2: R&D Bundle
On backorder
· Configured to order — request lead timeFrom materials teams running ATO Lab Plus Ultrasonic Metal Powder Atomizer – Reactive & Refractory Alloys | 20–120 µm
Unedited feedback from labs who bought and run ATO Lab Plus Ultrasonic Metal Powder Atomizer – Reactive & Refractory Alloys | 20–120 µm.
★★★★★
We validated our alloy on a trial batch first, then bought the system. Zero surprises bringing atomization in-house.
MK
Marcus K.
Materials Lead · Aerospace R&D
★★★★★
Asked about PSD control for a fine-cut powder. A materials engineer walked us through the parameters, not a sales pitch.
PS
Priya S.
Process Engineer · Medical Devices
★★★★★
Install and training were hands-on with people who atomize daily. Our first in-house batch met PSD spec.
DR
Diego R.
R&D Lead · University
Common questions
Don't see yours? Email [email protected] — NDA standard, typical reply within 4 hours.
What is ATO Lab Plus?
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.
What technology does ATO Lab Plus use?
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.
What are the main benefits of ATO Lab Plus?
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.
Is ATO Lab Plus suitable for laboratory use?
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.
Can ATO Lab Plus produce powder for metal 3D printing?
Yes. ATO Lab Plus produces powders suitable for LPBF/SLM, DED/laser cladding, Binder Jetting, Powder Metallurgy, MIM, HIP, SPS, and PPS applications.
How is particle size controlled?
Particle size distribution is controlled by selecting the appropriate ultrasonic frequency module. Higher frequencies produce finer powders, while lower frequencies generate coarser particles.
What particle size ranges are supported?
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.
What materials can be atomized with ATO Lab Plus?
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.
Is ATO Lab Plus suitable for reactive alloys?
Yes. The system operates in an inert atmosphere and produces low-oxygen powders, making it suitable for reactive materials and sensitive AM alloys.
How spherical is the powder produced?
ATO Lab Plus produces near-perfect spherical metal powders with smooth surfaces, resulting in excellent flowability and consistent additive manufacturing performance.
How repeatable are the results?
Ultrasonic atomization provides an ordered, stable process with excellent repeatability between batches, enabling reliable powder quality for R&D and production trials.
Does ATO Lab Plus support small batch production?
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.
What feeding systems are available?
ATO Lab Plus supports multiple feeding options, including Wire Feeding, Single Rod Feeding, Multi Rod Feeding, Revolver Rod Feeding, and custom feeders upon request.
What melting options are offered?
The standard configuration uses TIG melting, with induction melting available as an optional upgrade for specific materials and workflows.
Is ATO Lab Plus modular?
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.
How cost-effective is ATO Lab Plus compared to traditional atomizers?
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.
Does ATO Lab Plus help reduce material waste?
Yes. The ultrasonic atomization process minimizes material loss, and in-house production reduces dependency on external suppliers and excess powder purchases.
What industries use ATO Lab Plus?
ATO Lab Plus is used in additive manufacturing, materials research, academic laboratories, product development, and industrial R&D environments.
Can ATO Lab Plus integrate with other ATO 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.
Does ATO Lab Plus require complex infrastructure?
No. ATO Lab Plus is designed to install in a standard materials lab, not a dedicated powder plant. It runs on a 400 V 3-phase supply (up to 20 kVA), uses an argon inert-gas feed with atmosphere preparation in under 5 minutes, and is cooled by an external liquid chiller supplied with the system. Powder is captured by an integrated cyclone separator. At 1997 × 813 × 1626 mm and 600 kg it fits a normal lab footprint, so most facilities commission ATO Lab Plus without special construction or an industrial gas-atomization tower.
Is ATO Lab Plus currently available?
Yes. ATO Lab Plus is in stock and available for quotation.
How can I request pricing or technical guidance?
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.
Place your order, or talk to an engineer first
Order ATO Lab Plus Ultrasonic Metal Powder Atomizer – Reactive & Refractory Alloys | 20–120 µm direct, or talk to materials engineer