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ATO Sparq AI-Powered Ultrasonic Metal Powder Atomizer

With every system

Install, commissioning & training set up and dialed in at your site
Applications engineering alloy parameters + PSD targets for your materials

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

ATO Sparq AI-Powered Ultrasonic Metal Powder Atomizer

Ultrasonic metal powder atomization with AI-guided setup — 20–120 µm spherical powder, oxygen below 10 ppm, two camera views and remote supervision of several units.

AI suggests parameters for standard and new alloys
Reactive, refractory and standard alloys from wire, rod or scrap
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 AI-selected particle range

<10 ppm oxygen in reactive-alloy powder

3 modules ultrasonic frequencies: 20/35/52 kHz

50+ alloys already atomized on ATO

What your process engineer actually checks

We run these to make our own powder

Additive Plus operates ultrasonic atomization in-house through ATO Lab. We know how each alloy behaves at the sonotrode, the yield at fine LPBF fractions, and where oxygen creeps in — because we run it daily, not because a datasheet says so.

Full powder chain, one partner

Atomizer plus powder characterization (PSD, sphericity, flow) plus the AM system that prints it. The ATO suite — sieving, cleaning, feeding — integrates with Sparq, so you qualify a material and move it to production without stitching vendors together.

An applications engineer on the line

Run a paid trial atomization of your alloy before you commit.

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 Sparq base unit — TIG and plasma melting, patented half-wave nanoalloy sonotrode, AI-assisted control, two camera views, dual touchscreen, vacuum pump and cyclone
Large ATO powder container with fill monitoring
Ultrasonic frequency modules — 20, 35 or 52 kHz — to set the particle size
Feeding system: wire, single rod, multi rod, revolver rod or custom; Induction Melting System (IMS) as a module
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.

AI-guided setupParameter guidance for standard and new alloys, from your own run history

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

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

Two camera viewsLive image analysis of the process; remote supervision of several units

What the ATO Sparq is

The ATO Sparq is 3D Lab’s AI-powered ultrasonic metal powder atomizer. It uses the same patented ultrasonic process as the ATO Lab — feedstock melted on the tip of a nanoalloy sonotrode, an ultrasonic standing wave ejecting droplets of nearly equal size, spheres solidifying in cooled argon and collected by a cyclone — and adds a control layer built to keep that process in its window with less operator effort.

Two independent camera views and live image analysis watch the melt and the atomization. AI-guided parameter setup proposes starting conditions for standard alloys and for compositions the machine has never run, drawing on process data and the history of your own runs, which cuts the number of experimental trials when you qualify a new material. Every run is stored and can be compared or reproduced. Remote control and monitoring let one operator supervise several atomizers, and several Sparq units can be linked for synchronized, scalable production. Built-in diagnostics watch the consumables and tell the operator when maintenance is due. The AI assists; final settings and production decisions stay with your operator.

Specifications

Manufacturer	3D Lab, Warsaw, Poland
Process	Ultrasonic atomization, patented half-wave nanoalloy sonotrode
Control	AI-assisted parameter setup, live image analysis, two camera views, dual touchscreen, industrial PC, remote monitoring and control
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
Melting	TIG + 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 a large ATO powder container with fill monitoring, under argon
Cooling	liquid, external chiller
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 Sparq brochure and the ATO devices brochure are in the Downloads tab above.

What it gives your lab

Material qualification	New alloys and compounds in small batches, with fewer trial runs thanks to AI-guided setup
Reactive alloys	Ti, Zr-based alloys and intermetallics, under 10 ppm O₂
Refractory and HEA	Nb, Ta, W-based and high-entropy chemistries, melting points up to about 3100 °C
Scrap recycling	Feedstock and printing leftovers back into fresh powder
Small-batch production	Powder on demand instead of hundreds of kilograms bought to qualify one alloy
Repeatability	Every run logged and comparable; one operator can supervise several units

Alloys already atomized on ATO platforms include SS316L, Ti6Al4V, Inconel 625 and 718, NiTi, AlSi10Mg, Al7075, AZ31, CuCrZr, Nb, Ta, W90Ni7Fe3, AlCoCrFeNi, gold, platinum and silver alloys — more than fifty in all.

Videos of the ATO atomizers at work are in the Video tab above.

What the AI layer changes

Setup — AI-guided parametersInstead of starting a new alloy from a blank sheet, the operator gets suggested starting conditions based on process data and earlier runs. Fewer trial batches, less material spent on qualification.

Run — two camera viewsLive image analysis from two independent views helps keep the melt and atomization in the optimal window over longer runs, and the large powder container reports its fill level.

Scale — remote and multi-unitRemote monitoring and control let one operator supervise several atomizers, and Sparq units can be linked for synchronized production when one machine is no longer enough.

Powder made on ATO

Spherical powder made with ATO ultrasonic atomization. Images: 3D Lab material reports and case studies.

Spherical metal powder particles, ATO Sparq brochure — Spherical powder — ATO Sparq brochure

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

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

316L stainless steel powder atomized on an ATO atomizer — Stainless steel 316L — ATO

Peer-reviewed research on ultrasonic atomization

Published studies of the ultrasonic atomization method that the ATO Sparq is built on.

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.

Which feedstock you can use

The ATO Sparq takes the same feeding modules as the ATO Lab. 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. 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 Sparq is designed for labs and production rooms with ordinary utilities. 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 Sparq stops — and what to take instead

The AI layer makes the process easier to set up and repeat; it does not make one machine faster. Throughput is the same as the ATO Lab — up to about 0.3 L/h — so for more volume you add units, and for tonnes of one standard alloy buying gas-atomized powder remains cheaper. If your team prefers hands-on control of every parameter and does not need camera analysis or multi-unit supervision, the ATO Lab runs the same process. For gold, silver and platinum with Zero Loss recovery, take the ATO Noble. 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.

Make your own powder, measure it, print it

Put the ATO Sparq in front of a Microtrac CAMSIZER X2+ and one of our AO Metal LPBF printers and the loop closes inside your own laboratory: atomize an alloy, check its size distribution and sphericity, print it, feed the result back into the next run. Upstream, ATO Cast casts your alloy into rods; downstream, ATO Sieve sieves under argon and ATO Pure cleans and dries the powder. The same loop with the ATO Lab is offered as the R&D Bundle.

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 Sparq.

Book a visit at UC Irvine

In pictures

3D Lab ATO Sparq ultrasonic metal powder atomizer – AI-assisted in-house powder production — ATO Sparq — compact ultrasonic atomizer for labs and production floors. 1997 × 813 × 1626 mm / 78.6 × 32.0 × 64.0 in.

ATO Sparq ultrasonic atomization chamber – melt, sonotrode and cyclone powder collection — Inside the process chamber: melt source, cooled sonotrode, and inert-gas cyclone collection.

Spherical metal powders atomized on ATO – steel, titanium, nickel, aluminium and precious alloys — A sample of the 50+ alloys already atomized on ATO platforms — steel, Ti, Ni, Al, refractory and precious metals.

ATO metal powder production suite – atomizer, sieving, ultrasonic cleaning and feeding modules — Part of the ATO powder-production suite — sieving, cleaning, feeding and handling modules integrate with Sparq.

Availability, payment and delivery

Built to orderEach ATO Sparq 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 Sparq 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.

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 want a black box.”The AI proposes and monitors; it does not lock anything. All parameters remain open, every run is logged, and final settings and production decisions stay with your operator.

“Our operators are not atomization specialists.”That is the case the Sparq was built for: guided setup, camera monitoring and diagnostics that flag consumables take much of the routine work off the operator. On-site operator training is included in every quotation.

“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.

“We may need more volume later.”Add units rather than replace the machine: one operator can supervise several Sparq atomizers remotely, and they can be linked for synchronized production.

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	<10 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 Sparq brochure

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Product videos

What our customers say

★★★★★

“Harry and team were professional, effective communicators as we set up the order, then they executed quickly and produced an amazing product for us at a very competitive price. Am looking forward to our next print w Additive Plus!”

Luke DunningtonGoogle · Nov 2025

★★★★★

“Great 3D printing service and the resin parts look super smooth and clean. Really happy with how everything turned out!”

Laura SmithGoogle · Sep 2025

★★★★★

“Harry was very professional and helped me out with my 3D printing needs and explained what options I have in terms of filaments such as PEEK. Highly recommended.”

Steven FrancoGoogle · Oct 2026

★★★★★

“I needed a 3D enclosure printed urgently in a specific time period, they did great!”

IvoGoogle · Sep 2026

Common questions

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

What is ATO Sparq and who is it for?

ATO Sparq is an AI-powered ultrasonic metal powder atomizer made by 3D Lab. It produces spherical powder of 20–120 µm with a narrow particle size distribution and low oxygen from reactive and non-reactive alloys. It suits labs and production teams that qualify new materials, need repeatable small batches, or want one operator to run several atomizers.

How does ultrasonic atomization work in ATO Sparq?

Feedstock is melted by a TIG or plasma arc, or by induction, on the tip of a nanoalloy sonotrode. A piezoelectric transducer drives the sonotrode at ultrasonic frequency; the standing wave in the melt ejects droplets that solidify into spheres in cooled argon and are collected by a cyclone. Particle size follows the frequency: higher frequency gives finer powder.

What makes ATO Sparq different from gas or plasma atomizers?

Gas atomization needs a tall tower and large gas volumes and yields a broad size distribution; it is built for tonnage of one alloy. Ultrasonic atomization gives a narrow, frequency-set distribution in a compact machine, works in small batches and changes alloys quickly. On top of that, Sparq adds AI-guided setup and camera monitoring. Its throughput is lab to small-batch scale, not tonnage.

What particle sizes can ATO Sparq produce, and how is size controlled?

ATO Sparq produces 20–120 µm. Size is set by the ultrasonic frequency module — 20, 35 or 52 kHz: higher frequencies for fine LPBF/SLM fractions, medium for binder jetting and MIM, lower for DED, laser cladding and powder metallurgy. One machine can feed several processes by changing the module.

Which materials can ATO Sparq atomize?

Steels, titanium alloys, nickel superalloys, aluminum, magnesium, copper, refractory metals (niobium, tantalum, tungsten-based), precious metals and high-entropy alloys; intermetallics such as TiAl and NiTi have also been atomized on ATO platforms. Parameters are set per alloy according to melting point, oxygen affinity and composition.

Is ATO Sparq suitable for reactive alloys like titanium?

Yes. The chamber is evacuated and filled with argon in under 15 minutes, oxygen stays below 10 ppm during atomization, and the powder is collected under argon. Add the Passivation Module for reactive powders before they meet air.

Can ATO Sparq recycle scrap and feedstock?

Yes. In-house feedstock, machining scrap and printing leftovers can be fed back and atomized into fresh powder, depending on the feeding configuration. You make only the batch you need instead of buying tens or hundreds of kilograms to qualify one material.

How is ATO Sparq installed and supported through Additive Plus?

Additive Plus is the authorized US distributor of ATO. Installation and on-site operator training are included in every quotation, US service engineers support the system, and the warranty is 12 months. Lead time is 8–12 weeks after a confirmed order.

How much does ATO Sparq cost?

ATO Sparq is quoted to your configuration — melting, feeding and frequency modules and peripherals such as the chiller, ATO Sieve and ATO Clean. 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.

What does the AI in ATO Sparq actually do?

It guides parameter setup for standard and newly developed alloys using process data and the history of your runs, analyzes the process live through two camera views, and helps keep atomization in its optimal window. It assists the operator; it does not replace them, and all final settings stay under user control.

Can ATO Sparq reduce the time to qualify a new material?

Yes. AI-guided setup, process monitoring and access to earlier run data reduce the number of experimental trials, which saves development time and material when you introduce a new alloy.

Does ATO Sparq learn from previous runs?

It stores and analyzes data from completed runs, so you build your own knowledge base. Earlier runs can be reviewed and compared when you develop parameters for a new material or reproduce a proven process.

Is ATO Sparq autonomous?

It automates a significant part of routine setup and monitoring, and diagnostics tell the operator when consumables need maintenance. The operator remains responsible for supervision and final decisions.

Can one operator run several ATO Sparq units?

Yes. Remote control and process monitoring let one operator supervise several atomizers, and units can be linked for synchronized, scalable powder production.

Is ATO Sparq faster than ATO Lab?

No. Throughput is the same — up to about 0.3 L/h, depending on the alloy. Sparq makes setup and repeatability easier and scales by adding units.

What throughput does ATO Sparq offer?

Up to about 0.3 L of powder per hour. 3D Lab gives typical ATO 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 feeding systems are available?

Wire Feeding System, Single Rod, Multi Rod and Revolver Rod Feeding Systems, a crucible with the Induction Melting System for irregular pieces and scrap, and custom feeders on request.

What infrastructure does ATO Sparq need?

A 3-phase 400–440 V, 50/60 Hz supply (12–20 kW installed, about 4 kW average), argon of 5.0 purity at typically 15–25 L/min with about 90% recovered, compressed air, an external liquid chiller, and floor space for a 1997 × 813 × 1626 mm unit. No atomization tower is required.

Can I get a free powder sample?

Yes. Free powder samples of standard alloys are available, so you can test 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/.

Is ATO Sparq 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.

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

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

Place your order, or talk to an engineer first

Order ATO Sparq AI-Powered Ultrasonic Metal Powder Atomizer direct, or talk to materials engineer

Add to cart

ATO Sparq AI-Powered Ultrasonic Metal Powder Atomizer

What your process engineer actually checks

We run these to make our own powder

Full powder chain, one partner

An applications engineer on the line

What the ATO Sparq is

Specifications

What it gives your lab

What the AI layer changes

Powder made on ATO

Peer-reviewed research on ultrasonic atomization

Which feedstock you can use

Infrastructure and installation requirements

Where the ATO Sparq 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 Sparq brochure

Product videos

Send feedstock We atomizePowder + full data

Other products teams run alongside ATO Sparq AI-Powered Ultrasonic Metal Powder Atomizer

What our customers say

Common questions

Place your order, or talk to an engineer first