Free U.S. shipping on orders over $200 · Mutual NDA standard before any file review.
Talk to an engineer →
On backorder
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
On-demand production of spherical metal powder — AI-assisted ultrasonic atomization.
ATO Sparq is an AI-powered ultrasonic metal powder atomizer for laboratories and production teams that need fast material qualification, repeatable powder quality, and full control over particle size distribution — reactive and non-reactive alloys, produced when you need them.
- ✓ AI-assisted process control for repeatable, on-demand batches
- ✓ Spherical powder with tight, frequency-selected PSD
- ✓ Reactive & non-reactive alloys in a low-oxygen argon atmosphere
- ✓ Lead time: configured to order — request lead time
Price held 7 days after order.
Install + training included
Tailored service plan
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
Parameter sets validated against real print results across 50+ alloy families. Alloy setup, PSD targets, infrastructure planning — factory-trained engineers, sub-4h reply, NDA standard. Run a paid trial atomization of your alloy before you commit.
About this product
ATO Sparq is an AI-assisted ultrasonic metal powder atomizer that lets you make spherical, low-oxygen powder in-house — on demand, from reactive and non-reactive alloys, with particle size you select at the machine.
Why engineers choose ATO Sparq
Spherical powder, low oxygen, and PSD you control — without buying 100 kg to qualify one alloy.
AI-assisted process control
The system analyses atomization parameters and guides setup — even for alloys it has never run. That cuts trial-and-error and gives stable powder from the first batches.
Particle size you select
Multi-frequency ultrasonic modules (20 / 35 / 52 / 72 kHz) tune the output across a 20–120 µm range: fine for LPBF, medium for Binder Jetting and MIM, coarse for DED and laser cladding.
Low-oxygen, reactive-ready
An argon inert atmosphere set up in under 15 minutes, oxygen held below 10 ppm — suitable for titanium, zirconium, and other reactive and refractory alloys, not just steels.
On-demand, closed-loop
Make small qualification batches instead of buying hundreds of kilograms, and recycle in-house feedstock and scrap into fresh powder — lower qualification cost and less waste.
How ultrasonic atomization works
Molten metal, a vibrating sonotrode, and an inert atmosphere — spherical powder with almost no satellites.
Step 01
Melt the feedstock
Rods, wire, scrap, or irregular stock are melted at the sonotrode tip — TIG, induction, or plasma modules cover low- to high-melting alloys.
Step 02
Atomize with ultrasound
Ultrasonic vibration raises capillary waves on the melt pool; the waves eject uniform droplets, so particle size follows the selected frequency, not chance.
Step 03
Solidify & classify
Droplets cool into near-perfect spheres in an argon atmosphere, then a cyclone collects and a sieve classifies the powder to your target fraction.
Take control over particle size
One system covers several downstream processes. Select the frequency module to match the process you are feeding — the same machine serves multiple PSD targets:
| Frequency module | Powder fraction | Feeds |
|---|---|---|
| Higher frequency (52 / 72 kHz) | Fine | LPBF / SLM |
| Mid frequency (35 kHz) | Medium | Binder Jetting & MIM |
| Lower frequency (20 kHz) | Coarser | DED, laser cladding & PM |
PSD range 20–120 µm across the four modules. See the full specifications tab for throughput, power, and infrastructure figures.
Where teams run ATO Sparq
Honest use cases — material development, reactive and refractory powders, and closed-loop production.
Material qualification & R&D
New alloys and compounds, in small batches
Reactive-alloy powders
Ti, Zr, intermetallics — under 10 ppm O₂
Refractory & HEA
W, Mo, Ta and high-entropy chemistries
Precious-metal powders
Au, Pt, Ag — composition preserved
Scrap & feedstock recycling
Close the material loop in-house
Small-batch AM production
On-demand powder without external orders
Alloys already atomized on ATO
ATO ultrasonic atomization has been proven across a broad range of chemistries. A representative selection:
| Family | Examples |
|---|---|
| Steel | SS316L, SS304, 42CrMo4, 18Ni300, AMS5832 |
| Titanium | Ti Gr.1/2/5 (Ti6Al4V), Ti5Al2.5Sn, TiAl |
| Nickel | Inconel 625, Inconel 718, NiTi, NiTiHf |
| Aluminium | AlSi10Mg, Al7075, Al4047, AlMgSc |
| Refractory | Nb 99%, Ta 99%, W90Ni7Fe3, MoSi₂ |
| Precious & copper | Au 9–24 ct, Pt alloys, Ag 99%, CuCrZr, CuSn |
| HEA & special | CoCrFeMo, FeNiCrMo, AlCoCrFeNi, MoS₂ |
Atomization parameters depend on melting point, oxygen affinity, and composition — our engineers set them per alloy.
Not sure ATO Sparq is the right platform?
Compare the ATO ultrasonic atomizers — matched to your alloys, control style, and volume.
Tell us your target alloys, particle size, and batch volume — a materials engineer who runs ultrasonic atomization in-house will spec the ATO Sparq configuration around them and, if you want proof first, arrange a paid trial atomization of your alloy. Sub-4h reply, NDA standard.
Why source ATO Sparq through Additive Plus
- We run ultrasonic atomization ourselves through ATO Lab — this is equipment we operate, not just resell.
- Applications engineering: alloy setup, PSD targets, and parameter validation for your materials.
- Full ATO suite from one partner — atomizer, sieving, cleaning, feeding, and material handling.
- Install, commissioning and operator training included; tailored service and 12-month warranty.
- Paid trial atomization of your target alloy before you commit. <24h response · 200+ AM systems delivered 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 | <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 |
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 Sparq | AI-Powered Ultrasonic Metal Powder Atomizer
Atomizers · Ultrasonic atomization
ATO Pure | Ultrasonic Metal Powder Cleaning & Drying System
ATO Pure is an ultrasonic cleaning-and-drying station that reconditions used or freshly atomized metal powder — removing sub-5 µm fines, surface films and moisture, then drying it for reuse.
- ✓ Ultrasonic cleaning + integrated drying in one automated cycle
- ✓ Removes ultra-fine particles while preserving particle sphericity
- ✓ Recovers degraded powder — extends lifecycle, cuts material cost
- ✓ Lead time: configured to order — request current lead time
On backorder
· Configured to order — request lead time
Atomizers
ATO Passivation Module
The ATO Passivation Module is an automated safety system that passivates reactive metal powder — dosing controlled oxygen into the sealed container to build a protective oxide layer before it is opened.
- ✓ Controlled oxygen dosing builds a uniform protective oxide layer
- ✓ No ignition or explosion risk when the container is opened
- ✓ Automated, hands-off 1–2 hour cycle · works with ATO containers
- ✓ Lead time: configured to order — request current lead time
On backorder
· Configured to order — request lead time
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
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
Bundle · Ultrasonic atomization, Metal LPBF
AO Metal A50 + ATO Lab Plus + CAMSIZER X2: R&D Bundle
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 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
Prints Aluminium, Copper, HEA alloys, Magnesium, Nickel, Reactive metals, Refactory metals, Stainless Steel, Titanium
On backorder
· Configured to order — request lead time
Atomizers
ATO Clean Ultrasonic Cleaner for ATO Atomizers
ATO Clean ultrasonic cleaner is a machine specifically designed for cleaning the ATO series parts exposed to powder during the atomization stage, offering a convenient and effective cleaning.
On backorder
· Configured to order — request lead timeFrom R&D and production teams running ATO atomizers
Unedited feedback from materials and process engineers making powder in-house.
★★★★★
We qualified a new nickel superalloy in weeks instead of months — atomizing 2 kg at a time beat waiting on a 50 kg minimum order. The AI setup got us stable powder from the first runs.
MH
Dr. Martin Halvorsen Powder Metallurgy Lead · Aerospace R&D
★★★★★
Oxygen stayed under 10 ppm on our titanium runs and the PSD held batch to batch. Being able to select the fraction by frequency meant one machine fed both our LPBF and MIM work.
JO
Joyce Okafor Process Engineer · Medical Devices
★★★★★
Recycling machining scrap into printable powder in-house changed our material budget. One operator supervises both atomizers with the remote monitoring — no extra headcount.
LB
Luca Bianchi Additive Manufacturing Manager · Energy
Common questions
Don't see yours? Email [email protected] — NDA standard, typical reply within 4 hours.
What is ATO Sparq and who is it for?
ATO Sparq is an AI-assisted ultrasonic metal powder atomizer for laboratories and production teams that need spherical metal powder on demand. It produces high-sphericity powder with a controlled particle size distribution (20–120 µm), low oxygen content, and repeatable results across batches — from reactive and non-reactive alloys. ATO Sparq suits material qualification, R&D, and small-batch additive manufacturing, letting you make powder in-house instead of buying large minimum-order volumes just to test a single alloy.
How does ultrasonic atomization work in ATO Sparq?
ATO Sparq melts feedstock at a cooled sonotrode tip, then applies ultrasonic vibration to the molten metal. The vibration raises capillary waves that eject uniform droplets, which cool into near-perfect spheres in an inert argon atmosphere before a cyclone collects them. Particle size follows the ultrasonic frequency — higher frequencies produce finer powder, lower frequencies produce coarser powder — so the process is controlled rather than random. The result is spherical powder with high flowability and low satellite content.
What makes ATO Sparq different from gas or plasma atomizers?
ATO Sparq combines ultrasonic atomization with AI-guided process control. Compared with conventional gas or plasma atomization, it produces a tight, frequency-selected particle size distribution, works in small batches, and reaches stable powder quality far faster on new alloys. The AI analyses parameters and guides setup, cutting the trial-and-error that usually accompanies a new material. ATO Sparq is built for on-demand, in-house production and material development rather than large-tonnage commodity powder runs.
What particle sizes can ATO Sparq produce, and how is size controlled?
ATO Sparq produces powder across a 20–120 µm range. Size is controlled through multi-frequency ultrasonic modules (20, 35, 52 and 72 kHz): higher frequencies yield finer powder for LPBF/SLM, mid frequencies suit Binder Jetting and MIM, and lower frequencies produce coarser fractions for DED, laser cladding and powder metallurgy. Because one system covers several PSD targets, you can feed different downstream processes from the same machine by selecting the appropriate frequency module.
Which materials can ATO Sparq atomize?
ATO Sparq handles both reactive and non-reactive metals: steels, titanium and titanium alloys, nickel superalloys, aluminium, magnesium, refractory metals (tungsten, molybdenum, tantalum), precious metals, copper alloys, and high-entropy alloys. Intermetallics such as TiAl, NiAl and NiTi have also been atomized on ATO platforms. AI-assisted setup and modular melting (TIG, induction or plasma) stabilise atomization even for difficult chemistries. Atomization parameters are set per alloy based on melting point, oxygen affinity and composition.
Is ATO Sparq suitable for reactive alloys like titanium?
Yes. ATO Sparq operates in an argon inert atmosphere that is prepared in under 15 minutes and holds oxygen below 10 ppm, which is essential for reactive materials such as titanium and zirconium alloys. Low oxygen pickup keeps the powder suitable for demanding additive manufacturing and preserves alloy chemistry. For the most reactive materials our engineers set atmosphere and process conditions per alloy, and can run a paid trial atomization of your material before you commit to the system.
Can ATO Sparq recycle scrap and feedstock?
Yes. ATO Sparq lets you recycle in-house feedstock and machining scrap into fresh spherical powder, closing the material loop. Instead of buying hundreds of kilograms to qualify a material or replacing powder from external suppliers, you produce what you need on demand. This lowers material waste, reduces qualification cost, and shrinks the environmental footprint of powder sourcing — one reason teams use ATO Sparq for both R&D and sustainable small-batch production.
How is ATO Sparq installed and supported through Additive Plus?
Additive Plus runs ultrasonic atomization in-house through ATO Lab, so support comes from engineers who operate the process, not a remote ticket queue. Every system includes install, commissioning and operator training, a tailored service plan, and a 12-month warranty. ATO Sparq is quoted and configured to order — request a quote for pricing and current lead time. The full ATO suite (sieving, cleaning, feeding and handling) is available from the same partner, and a paid trial atomization of your alloy can be arranged before purchase.
Place your order, or talk to an engineer first
Order ATO Sparq | AI-Powered Ultrasonic Metal Powder Atomizer direct, or talk to materials engineer