Amazemet Unveils Powder2Powder Atomiser for Sustainable Metal Powder Recycling at Formnext 2024

Innovative Technology for Metal Powder Recycling and Custom Alloy Production
Amazemet, a Warsaw-based Polish company, will introduce its groundbreaking Powder2Powder (P2P) atomisation system at Formnext 2024, offering a versatile solution for recycling metal powders and producing custom alloy powders directly from feedstock. The P2P system, which combines plasma processing and ultrasonic atomisation, is designed to convert oversized or irregular metal powders into highly spherical, satellite-free particles optimised for Additive Manufacturing (AM). This technology is unique in that it allows the powder size to be independent of the initial feedstock, enabling the direct atomisation of pulverised titanium feedstock—something not possible with traditional plasma spheroidisation methods.

Łukasz Żrodowski, inventor and CEO of Amazemet, shared, “The Powder2Powder system is a leap forward in powder recycling. It not only addresses the issue of powder waste but also enables manufacturers to customise powder compositions, enhance sphericity, and optimise particle size distribution—critical factors in the AM industry.”

Key Benefits for Additive Manufacturing (AM)
The P2P system has already shown impressive results in trials using titanium (Ti) alloy powders. The technology operates at a frequency of 40 kHz, achieving highly consistent results, including an aspect ratio (D50) exceeding 0.95 and a precise particle size distribution (D90 < 80 µm). Nearly 97% of the resulting powder is suitable for AM processes such as Laser Beam Powder Bed Fusion (PBF-LB), Directed Energy Deposition (DED), and Electron Beam Powder Bed Fusion (PBF-EB). These results demonstrate the potential for the Powder2Powder system to significantly improve sustainability in metal powder production by enabling the recycling of otherwise unusable powders into high-quality AM material.

Moreover, the P2P system’s ability to process elemental powders into homogeneous pre-alloyed materials is a significant advantage. For instance, tests with titanium and 10% molybdenum (Mo) elemental powders showed that the system could form consistent alloy powders directly from base materials, offering a solution for developing custom alloys without the need for complicated preprocessing.

Features and Advantages of the Powder2Powder System

• Precision Control of Particle Size Distribution (PSD): The P2P system can control the particle size distribution, transforming oversized and irregular particles into AM-optimised powder, ideal for a range of AM techniques.

• Enhanced Powder Morphology: The combined use of plasma-based melting and ultrasonic atomisation refines particle morphology, producing highly spherical, satellite-free particles, which enhance AM performance and powder flowability.

• Custom Alloy Production: The system can process elemental powders or commercial alloys and create pre-alloyed materials directly, enabling rapid development of new alloys without the need for complex preprocessing steps like electrode casting or wire drawing.

• Multi-Material Compatibility: The P2P system supports a wide range of materials, including steel, titanium, nickel, refractory alloys, and high-entropy alloys (HEAs), providing flexibility for various AM applications across industries.

• Sustainability and Waste Reduction: By enabling the recycling of metal powders and reducing waste, the P2P system supports sustainable manufacturing practices. It turns otherwise unusable powders into material suitable for AM, contributing to the reduction of industrial waste.

Transforming the AM Industry with Custom Powder Solutions
Amazemet’s Powder2Powder system promises to be a game-changer for the Additive Manufacturing sector by addressing two key challenges: upcycling powder waste and producing custom alloy powders. The system’s ability to recycle and tailor metal powders directly from base materials enhances both efficiency and sustainability in powder-based manufacturing. It provides manufacturers with the flexibility to create highly customised, high-performance powders for a variety of AM processes, such as aerospace, automotive, and biomedical applications.

The Powder2Powder system will be on display at Formnext 2024, where attendees will have the first opportunity to see its capabilities in action. Amazemet will be showcasing the system at Hall 12, E61, offering a comprehensive solution for both recycling and custom alloy powder production.