AMAZEMET develops laser-based melting system for improved ultrasonic atomization

The company AMAZEMET has developed a new high-energy laser system designed to improve the efficiency and purity of ultrasonic atomization. The innovation was realized as part of an EU-funded project and is intended to optimize the production of high-performance metal powders. Compared to conventional TIG or plasma-based melting processes, laser-based energy input provides a more precise and cleaner heat source. This enables more efficient atomization of high-performance materials and reduces the risk of contamination.

The new melting system will be integrated into AMAZEMET’s rePowder atomization platform, expanding the possibilities in metal powder processing.

Łukasz Żrodowski, inventor and CEO at AMAZEMET, explains “Laser-beam unlock new capabilities in ultrasonic atomization. The integration of a precise and highly concentrated heat source allows us to expand the range of materials that can be effectively atomized. By eliminating contamination risks associated with traditional plasma sources, we achieve cleaner, more controlled atomization with improved powder quality. The ability to fine – tune the energy input of 6kW laser through advanced scanning strategies enables new level of process control for high-performance materials, like C103. We are confident that laser-based ultrasonic atomization will redefine industry standards in powder manufacturing.”

A key feature of the system is the ability to fine-tune the 6 kW laser using advanced scanning strategies. This allows different materials to be processed efficiently, from light metals such as aluminum to difficult-to-melt materials such as titanium and niobium. In addition, there is no need for consumable electrodes, which prevents contamination by tungsten or other undesirable elements. The technology is based on findings from the additive manufacturing processes Laser Powder Bed Fusion (L-PBF) and Electron Beam Powder Bed Fusion (EB-PBF) and enables more precise control of the melting process.

The integration of the laser-based melting system into the rePowder platform marks a step forward in sustainable metal powder production. AMAZEMET continues to focus on the development of new material processing methods and protects its technologies through an extensive patent portfolio. Further technical details are expected to be released in the coming months of 2025.