Made to order
- Install, commissioning & training set up and dialed in at your site
- Applications engineering feeding setup + atomizer integration
ATO Wire Feeding System for Ultrasonic Metal Atomizers
Continuous, automated wire feed for your ATO ultrasonic atomizer — standard welding-market wire, reactive or non-reactive, on extended spools.
- Extended spools · fewer changes, longer runs
- Reactive and non-reactive wire from the welding market
- Installation, on-site operator training and US service included in every quotation
- Lead time 8–12 weeks · 12-month warranty
What your process engineer actually checks
Uptime, not spool changes
Extended-spool capacity means fewer reloads and fewer interruptions. A continuous, automated wire feed keeps the atomizer producing spherical powder instead of waiting on an operator to reload.
Feedstock freedom
The system adapts to wire widely available on the welding market, reactive and non-reactive — so you source feedstock on the open market instead of being locked to a single supplier.
An applications engineer on the line
We run ATO ultrasonic atomization in-house through ATO Lab.
- Wire Feeding System (WFS) for your ATO ultrasonic atomizer
- Set up for extended wire spools
- Automated atomization with optimized parameters for your wire
- Optional ATO Wipe to clean the wire before it reaches the melt
- Installation and on-site operator training — included in every quotation
What the ATO Wire Feeding System is
The ATO Wire Feeding System (WFS) is a 3D Lab accessory that feeds wire from a spool into an ATO ultrasonic metal atomizer. The wire melts at the sonotrode and is atomized into spherical powder while the feed continues, which turns atomization into a continuous, automated process with optimized parameters instead of a series of manual loads.
It handles reactive and non-reactive materials and is adaptable to wires available on the welding market, so feedstock can be bought from ordinary wire suppliers. Extended wire spools reduce the number of spool changes, which keeps the atomizer producing powder for longer between operator interventions. 3D Lab describes the WFS as available with a basic ATO configuration.
Specifications
| Type | Wire feeding accessory for ATO ultrasonic metal atomizers |
| Fits | ATO ultrasonic atomizers; listed by 3D Lab among the optional modules of the ATO Lab and used with ATO Sparq feeding options |
| Feedstock | Wire on spools, reactive and non-reactive materials |
| Wire sourcing | Adaptable to wires available on the welding market |
| Spools | Extended wire spools supported |
| Process | Continuous, stable, automated, with optimized parameters |
| Construction | Built for continuous use |
| Manufacturer | 3D Lab, Poland |
| Installation and training | On site, included in every quotation |
| Warranty | 12 months, US service engineers |
| Lead time | 8–12 weeks |
3D Lab does not publish wire diameters or feed rates for the WFS; the quotation states them for your alloy and atomizer.
What it changes in your powder workflow
Wire feed is the route to choose when the atomizer is meant to produce, not just to experiment:
| Run length | extended spools mean longer runs between reloads |
| Operator time | automated feed reduces manual intervention and labor cost |
| Feedstock supply | standard welding-market wire instead of custom-made rods |
| Materials | reactive and non-reactive alloys on the same system |
| Repeatability | a stable, continuous process with optimized parameters |
If the alloy you need is not available as wire, cast it into rods with ATO Cast and use a rod feeder, or melt it in a crucible with the Induction Melting System.
How the Wire Feeding System runs
Where the Wire Feeding System stops — and what to take instead
The WFS needs an ATO ultrasonic atomizer — it is a feeder, not a standalone machine — and it feeds wire: if your alloy does not exist as wire, it is the wrong path. For cast or machined rods take the Single Rod Feeding System (1–10 mm, up to 110 mm) or the Multi Rod Feeding System (4–10 mm, up to 1200 mm in total). For scrap and irregular pieces, or alloys with volatile elements, the Induction Melting System melts the charge in a crucible. Wire with surface contamination goes through ATO Wipe first.
Make your own powder, measure it, print it
The WFS keeps an ATO ultrasonic atomizer running on standard wire; the rest of the loop is the same. Atomize spherical powder in the 20–120 µm range, check size distribution and sphericity on a Microtrac CAMSIZER X2+, print it on an AO Metal LPBF printer, and repeat. The atomizer, analyzer and printer are also offered together as the R&D Bundle.
See it running in California
You can see an ATO atomizer running in California, at UC Irvine (UCI). Book your visit on our visit page. Book a visit at UC Irvine
In pictures
Availability, payment and delivery
Why buy it through Additive Plus
What usually stops people — and the honest answer
Ready when you are
| Brand | 3D Lab |
| Country of origin | Poland |
Product videos
We run custom batches too. Try before you build the capability.
Want to validate an alloy before buying the system? Our ATO lab runs a custom batch for you in 3–4 weeks — biocompatible, refractory, proprietary — so you see real powder before committing to in-house atomization.
Other products teams run alongside ATO Wire Feeding System for Ultrasonic Metal Atomizers
Ultrasonic cleaning of every ATO atomizer component that touched powder — all parts at once, hands-free, in less than 30 minutes — so the next alloy starts clean.
- Removes residue between material groups — no carry-over into the next batch
- Double-filtration water system for a longer bath life
- Installation, training and US service included · free powder samples
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation included
Sieve metal AM powder in an argon atmosphere, straight from the ATO atomizer powder container — ultrasonic vibration keeps the mesh open and the powder away from oxygen.
- Same powder container as the ATO atomizers — transfer under argon
- Screens chosen for your target cut · optional oxygen sensor
- Installation, training and US service included · free powder samples
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation included
Atomize your own alloy, measure the powder and print it — the ATO Lab, the Microtrac CAMSIZER X2+ and the AO Metal A50 as one materials-development cell from one supplier.
- ATO Lab: 20–120 µm spherical powder, oxygen below 10 ppm
- CAMSIZER X2+: size and shape from 0.9 µm to 8 mm in 1–3 minutes
- A50: Ø50 × 100 mm LPBF, every laser parameter open
- Installation and training included · 8–14 weeks · 12-month warranty
Made to order
· Lead time 8–14 weeks · installation included
Ultrasonic and brush cleaning of wire and rod feedstock before it reaches the ATO atomizer — set the cleaned length or weight and let it run.
- Wire on spools, plus a rod mode for the Single Rod Feeding System
- Automatic and manual modes · integrated safety sensors
- Installation, training and US service included · free powder samples
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation included
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
Made to order
· Lead time 8–12 weeks · installation included
Make your own gold, silver and platinum powder, measure it and print it — the ATO Noble, the Microtrac CAMSIZER X2+ and the AO Metal A100 as one precious-metal cell from one supplier.
- ATO Noble: Au 9 ct to 99.99%, Ag, Pt, Pd, Ir with Zero Loss recovery
- CAMSIZER X2+: size and shape from 0.9 µm to 8 mm in 1–3 minutes
- A100: Ø100 × 100 mm LPBF, optional blue laser for gold and silver
- Installation and training included · 8–14 weeks · 12-month warranty
Made to order
· Lead time 8–14 weeks · installation included
Make freshly atomized reactive powder safe to open — automated, controlled oxygen dosing builds a thin protective oxide layer inside the 3D Lab powder container.
- Automated passivation cycle of 1–2 hours, depending on the material
- Designed for opening the container with no ignition or explosion risk
- Installation, on-site operator training and US service included in every quotation
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation included
Cast your own feedstock rods for ATO atomizers — from any alloy you design or from AM scrap — with pre-melt purification and induction melting under vacuum.
- Built-in resistance furnace purifies the charge before casting
- 120 mm rods for the Revolver Rod Feeding System · re-cast AM scrap
- Installation, training and US service included · free powder samples
- Lead time 8–12 weeks · 12-month warranty
Made to order
· Lead time 8–12 weeks · installation includedWhat 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!”
“Great 3D printing service and the resin parts look super smooth and clean. Really happy with how everything turned out!”
“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.”
“I needed a 3D enclosure printed urgently in a specific time period, they did great!”
Common questions
Don't see yours? Email [email protected] — NDA on request, typical reply within 4 hours.
What does the ATO Wire Feeding System do?
What wire can I use — am I locked to one supplier?
How do extended spools help?
Which ATO atomizers is it compatible with?
Does it work for reactive metals?
Is the Wire Feeding System part of the standard atomizer?
What wire diameters does it take?
Should the wire be cleaned before atomization?
Which alloys can I atomize from wire?
How much does the ATO Wire Feeding System cost?
What is the lead time and warranty for the ATO Wire Feeding System?
Can I get a free powder sample or a trial atomization?
Can I see an ATO atomizer running?
Place your order, or talk to an engineer first
Order ATO Wire Feeding System for Ultrasonic Metal Atomizers direct, or talk to materials engineer