Made to order

$Custom Alloy Metal Powder — Atomized to Your Composition | Reactive, Refractory & High-Entropy Alloys$

What you get

Measured powder data — PSD, chemistry, oxygen and flow
NDA-protected handling — your composition stays confidential

Materials, Metal Powders 3D Printing Materials · Ultrasonic atomization

Custom Alloy Metal Powder — Atomized to Your Composition | Reactive, Refractory & High-Entropy Alloys

Bring a composition the catalog doesn’t cover — we ultrasonically atomize your alloy into fine, spherical, low-oxygen metal powder at a target 20–120 µm PSD, characterize every batch, and ship it print-ready with the measured powder data.

✔ Reactive, refractory, intermetallic or high-entropy — from rod, wire, ingot or scrap
✔ Frequency-selected particle size for LPBF, DED, MIM or binder jetting
✔ Every batch characterized — measured PSD, chemistry, O₂ and flow shared with you
✔ NDA standard · feasibility check first · quoted per composition

NDA standard Quoted per composition

Premium-gradegas-atomized LPBF powder

COAon request

Card, PayPal or POtax-exempt certificate accepted

100 kg+volume quote

What your process engineer actually checks

Built on a proven atomization process

Many families on this card — reactive, refractory, intermetallic, high-entropy — have already been atomized on ATO ultrasonic systems. You get frequency-selected 20–120 µm powder with low oxygen and measured PSD, chemistry and flow — a proven process matched to your composition.

A materials engineer on the line

Send your target composition, particle size and batch size — we atomize these alloys on ATO ultrasonic systems and confirm whether yours is feasible, plus the frequency configuration, before you commit. Sub-4h reply, NDA standard.

About this product

Custom Alloy is made-to-order metal powder: you bring a composition the catalog doesn’t cover — a proprietary blend, a reactive or refractory metal, an intermetallic or a high-entropy alloy — and we ultrasonically atomize it into fine, spherical, low-oxygen powder. Particle size is set by ultrasonic frequency across a 20–120 µm range, and every batch is characterized so you get the measured PSD, chemistry, oxygen and flow. Many of the alloy families below have already been atomized on ATO ultrasonic systems — a strong starting point for your composition. Send us your target chemistry and we’ll confirm whether we can atomize it.

Spherical metal powder atomized on an ATO ultrasonic system for custom alloy production — Representative spherical powder atomized on an ATO ultrasonic system.

Why order a custom alloy through Additive Plus

Spec-backed reasons R&D and production teams atomize with us instead of waiting on a catalog powder.

Your composition, not a catalog grade

Bring the exact chemistry your application needs — reactive, refractory, intermetallic or high-entropy. We atomize compositions no off-the-shelf powder covers, including proprietary and recycled feedstock.

Frequency-selected particle size

Ultrasonic atomization gives a narrow 20–120 µm distribution set by the frequency module — not random turbulence. Request a fine cut for LPBF or a coarser fraction for DED, MIM or binder jetting.

Low-oxygen, spherical, satellite-free

Atomization under inert argon keeps oxygen pickup low and yields near-spherical, low-satellite powder with an unoxidized surface and high flowability. Every batch is characterized for PSD, chemistry, oxygen and flow, and we share the measured values.

Trial batch before you scale

Start with a small qualification batch to prove the powder in your process, then scale the same composition. NDA standard — your chemistry stays yours.

From your spec to qualified powder

How Additive Plus turns your composition into print-ready powder.

Step 01

Define spec & feedstock

Share the composition, target particle size, batch size and downstream process under NDA. You send rod, wire, ingot or scrap, or we source the master alloy.

Step 02

Ultrasonic atomization

We atomize under an inert argon atmosphere on ATO ultrasonic systems — low oxygen pickup, high sphericity, particle size selected by ultrasonic frequency.

Step 03

Qualify & deliver

Sieve, clean and passivate, then characterize PSD, chemistry, oxygen and flow. Powder ships print-ready with its measured values.

What to include in your quote request

The more of this you share up front, the faster and tighter the quote. Send it under NDA.

Target composition

An element list in wt% or at%, or a reference grade for us to match (for example “Inconel 625-like”). Attach a spec sheet if you have one.

Process & particle size

Your downstream process — LPBF, DED, MIM, binder jetting or coatings — and the target fraction or D10 / D50 / D90.

Batch size & cadence

The trial or qualification quantity you need now, plus the repeat volume you expect once the alloy is proven.

Feedstock route

Whether you’ll supply rod, wire, ingot or scrap, or you’d like Additive Plus to source the master alloy.

Requirements

Any oxygen limit, target particle-size fraction or specification the powder must meet for your qualification.

Proven, Already-Atomized Compositions

The ATO ultrasonic process handles metals with melting points up to 3400 °C. These alloys have already been atomized on ATO systems — bring one of them, a close variant, or your own composition in the same family, and we’ll confirm feasibility.

Family	Already-atomized grades
Steel & stainless	SS316L · SS304 · 42CrMo4 · PH17-7 · FeMn · Fe 99.5% · AMS5832
Titanium	Ti Gr.1 · Gr.2 · Gr.5 (Ti6Al4V) · Ti5Al2.5Sn · TiAl · TiMoSi
Nickel	Inconel 625 · Inconel 718 · NiTi · NiTiHf · Ni 99%
Aluminium	AlSi10Mg · Al7075 · Al4047 · Al5183 · AlMg · AlMgCu · AlMgSc · AlCoCrFeNi · Al 99.99%
Magnesium	AZ31 · WE43 · WE54 · ZX00 · MgAl9Zn1
Copper	CuCrZr · CuSn · CuNi3Si · CuAlNiFe · CuMnAl · CuM1E
Refractory	Nb 99% · Ta 99% · W90Ni7Fe3 · MoSi2
Precious	Au 9ct / 18ct / 99.99% · Ag 99% · Pt alloys · Ir 99%
High-entropy (HEA)	CoCrFeMo · CoCrFe · NiCrFe · FeNiCrMo · FeNiAlCr
Special	MoS₂ · B₄C · Zr bulk metallic glass

Don’t see your alloy? If it can be melted and welded, it can most likely be atomized — send us the composition and we’ll confirm feasibility.

Atomization Capability

Parameter	Custom Alloy powder
Particle size (PSD)	20–120 µm, frequency-selected · fine cut for LPBF, coarser for DED / MIM / binder jetting
Melting point range	Up to 3400 °C — reactive, refractory and high-entropy metals
Atmosphere	Inert argon — low oxygen pickup, high sphericity
Powder morphology	Near-spherical, low-satellite, unoxidized surface — high flowability for LPBF and DED
Input feedstock	Rod · wire · ingot · scrap / recycled material · or master alloy sourced by us
Characterization	PSD, chemistry, oxygen and flow measured and reported per batch
Batch model	Trial / qualification batch → repeat at production volume

ATO ultrasonic atomizer chamber where custom alloys are atomized under argon — Custom alloys are atomized under an inert argon atmosphere on ATO ultrasonic systems.

Typical Applications

Alloy development

New compositions before committing to a production powder

LPBF & DED R&D

Fine or coarse cuts for laser powder-bed and directed energy deposition

HEA & intermetallics

High-entropy alloys, TiAl / NiTi and other hard-to-source systems

MIM & binder jetting

Medium fractions for metal injection molding and binder jetting

Thermal spray & coatings

Flowable fractions for HVOF, plasma spray and laser cladding

Brazing, sintering & PM

Powders for brazing/soldering, MIM and press-and-sinter powder metallurgy

Recycled-powder programs

Turn qualified scrap and machining stock back into spherical powder

University & institute labs

Small-batch research powder in compositions no supplier stocks

Not sure a custom alloy is the right route?

Standard gradeA-Powder catalogUS-made stock powders (316L, IN718, Ti6Al4V…) ready to shipView powders →
Make it yourselfATO LabBenchtop ultrasonic atomizer to produce your own powder in-houseView atomizer →
Precious metalsATO NobleZero-waste atomization for gold, silver and platinum-group powdersView atomizer →

Tell us your target composition, particle size and batch size — a materials engineer will confirm whether it’s feasible to atomize, the frequency configuration and lead time, and send a quote if we can produce it. Sub-4h reply, NDA standard.

Why Source Custom Alloy Powder Through Additive Plus

Atomization runs on ATO ultrasonic systems — the same technology behind our ATO Lab atomizers and AO Metal powders.
Applications engineering matches melting module, feeding system and frequency to your alloy before atomization.
Full powder workflow coordinated by one partner: atomization, sieving, cleaning, passivation and characterization.
NDA standard on every composition · sub-24h engineer response.
15,000+ teams supported across 23 countries.

Compatible 3D printing systems

Atomized to the process and cut you specify.

LPBF / DMLS

EOS · SLM · Renishaw · Farsoon · and more

DED / DMD

InssTek · Optomec · Meltio

Binder Jetting

Desktop Metal · HP · ExOne

Metal Injection / cold spray

MIM feedstock · thermal spray

We atomize to your target composition and particle-size distribution for your process — LPBF, DED, binder jetting, MIM or cold spray — including reactive, refractory and high-entropy alloys. Tell us the alloy, the cut and the machine.

Brand	AO Metal
Technology	Ultrasonic atomization
PSD (particle size distribution)	20–120 micrometres
Printing Materials	Metal Powders
Material	Custom Alloy
Production Method	Ultrasonic Atomized
Country of origin	China, USA OEM
Application	Engineering, Manufacturing

Product videos

Common questions

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

What is a custom alloy powder and how is it made?

A Custom Alloy powder is metal powder atomized to your own composition instead of a catalog grade. You supply the chemistry — or feedstock as rod, wire, ingot or scrap — and Additive Plus atomizes it ultrasonically under an inert argon atmosphere into fine, spherical, low-oxygen powder. Particle size is selected by ultrasonic frequency across a 20–120 µm range, and every batch is characterized for PSD, chemistry, oxygen and flow, so you receive the measured powder data.

Which alloys can you atomize?

Custom Alloy covers reactive, refractory, intermetallic and high-entropy systems that catalog powders rarely offer. Families already atomized on ATO systems include titanium (Ti6Al4V, TiAl), nickel (Inconel 625/718, NiTi, NiTiHf), steels and stainless (SS316L, 42CrMo4, PH17-7), aluminium (AlSi10Mg, Al7075), magnesium (AZ31, WE43), copper (CuCrZr, CuSn), refractory metals (Nb, Ta, W90Ni7Fe3), precious metals and high-entropy alloys. The process handles melting points up to 3400 °C. If your metal can be melted and welded, it can most likely be atomized — send the composition and we confirm feasibility.

Do you sign an NDA before I share my composition?

Yes. An NDA is standard on every Custom Alloy inquiry. Your chemistry, feedstock and application stay confidential — we treat a proprietary composition as your intellectual property, not ours. Additive Plus atomizes it, characterizes it, and returns the powder together with its measured data — particle size distribution, chemistry, oxygen and flow. Share your target composition and a materials engineer will confirm feasibility under NDA before any commitment.

What particle size can I get, and for which process?

Custom Alloy powder is produced across a 20–120 µm range, with the fraction set by the ultrasonic frequency module rather than random turbulence. Request a finer cut for LPBF laser powder-bed fusion, or a coarser, more flowable fraction for DED, MIM or binder jetting. Tell us your downstream process and target D-values and we configure the atomization to match, then report the achieved PSD in the batch measurement data.

Do I supply the feedstock, or can Additive Plus source it?

Both work. You can send your own feedstock — rod, wire, ingot, or qualified scrap and machining stock — and we atomize it directly, which is ideal for recycled-powder programs. Or Additive Plus sources the master alloy to your specified composition. Either way, the Custom Alloy powder is atomized under argon, characterized, and delivered with the measured PSD, chemistry, oxygen and flow reported.

Do you provide a Certificate of Analysis for a custom alloy?

Because a custom alloy is a made-to-order, non-standard composition, Additive Plus does not issue a formal Certificate of Analysis or material certificate for it. What you do get is full characterization: every batch is measured for particle size distribution, chemistry, oxygen and flow, and we share those results so you can qualify the powder in your own process. Formal certification against a public standard applies to catalog grades, not bespoke Custom Alloy compositions.

What is the minimum batch size and lead time?

Minimum batch and lead time depend on the alloy, the target particle size, and whether you supply feedstock or we source it — so both are confirmed per composition when we quote. The typical path is a small trial or qualification batch to prove the powder in your process, followed by repeat batches at production volume. Send your composition, target PSD and batch size and a materials engineer will return a Custom Alloy quote with the exact minimum and lead time.

Can a custom alloy scale from a trial batch to production?

Yes. Custom Alloy is built to move from a trial batch to repeatable production of the same composition. Because particle size is frequency-selected and each batch is characterized against your spec, later batches reproduce the qualified powder rather than drift. Once a composition is proven, Additive Plus repeats it at production volume and can integrate sieving, cleaning and characterization so every lot ships print-ready with its measured powder data.

Can you atomize powder for thermal spray, MIM or brazing — not just 3D printing?

Yes. Custom Alloy powder is most often used for LPBF and DED additive manufacturing, but the same ultrasonic atomization produces flowable, spherical powder for thermal spray and coatings (HVOF, plasma spray, laser cladding), metal injection molding, press-and-sinter powder metallurgy, and brazing or soldering. Tell us the process and we select the particle-size fraction to match — coarser and more flowable for spray and DED, finer for LPBF and MIM.

Place your order, or talk to an engineer first

Order Custom Alloy Metal Powder — Atomized to Your Composition | Reactive, Refractory & High-Entropy Alloys direct, or talk to materials engineer

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