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- 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
Price held 7 days after order.
NDA standard
Quoted per composition
What your process engineer actually checks
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.
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 |
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 catalogView powders →
Make it yourselfATO Lab PlusView atomizer →
Precious metalsATO NobleView atomizer →
Make it yourselfATO Lab PlusView atomizer →
Precious metalsATO NobleView 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.
| Brand | AO Metal – High-Precision Metal 3D Printers for Innovation |
| Technology | Ultrasonic atomization |
| PSD (particle size distribution) | 20–120 micrometres |
| Printing Materials | Metal Powders |
| Material | Custom Alloy |
| Production Method | Ultrasonic Atomized |
Product videos
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We atomize qualified reactive-metal scrap and machining stock back into spherical, print-ready powder — closing your recycled-material loop under one partner.
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Unedited feedback from materials and process leads.
★★★★★
We needed a NiTiHf batch nobody stocks. It came back spherical, low-oxygen, and printed first try on our LPBF system — the measured chemistry matched our target.
DR
Daniel R. Materials Lead · Aerospace R&D
★★★★★
We sent qualified Ti-6Al-4V machining stock and got print-ready powder back with the measured data we needed. It finally closed our recycled-powder loop instead of scrapping the material.
EM
Elena M. Process Engineer · Medical Devices
★★★★★
Our high-entropy composition atomized cleanly at the fraction we asked for. The trial batch let us validate the alloy before committing to a production run.
TB
Thomas B. R&D Director · Energy
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 and its Certificate of Analysis to you. 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