This year’s advancements at TMS 2026
This year at TMS, we are demonstrating three key developments designed to enhance the efficiency, flexibility, and operational accuracy of alloy development and powder production. We are introducing the AI-Driven Process Automation system, an integrated upgrade that enables autonomous operation of the rePOWDER platform, alongside the expanded material capability provided by our new Laser Melting Source. Finally, we are formally launching our Atomization Services, providing researchers and engineers direct, cost-effective access to custom, small-batch metal powders produced with ultrasonic atomization technology.
FREEDOM IN METAL AM
DEVELOPMENT & PRODUCTION
Advancing Ultrasonic Atomization through Ai-Driven Process Control
While ultrasonic atomization is valued for its narrow particle size distribution and low gas consumption, its use has historically been limited by productivity rates. This session examines how machine learning and image processing are being utilized to automate the process. By implementing Ai-driven autonomous control, we aim to enable extended, unattended operation, significantly increasing the feasibility of overnight production for research environments.
Speaker: Bartosz Morończyk
Date: Tuesday, March 17, 2026
Time: 5:30 PM – 6:30 PM
Location: Exhibit Hall G
Ultrasonic Atomization of Lightweight Alloys for Additive Manufacturing: Processing of Al- and Mg-Based Alloys
This presentation focuses on the specific challenges and results of processing aluminum and magnesium-based alloys. We will discuss how ultrasonic atomization handles these lightweight, reactive materials to produce high-quality spherical powder suitable for Additive Manufacturing (AM) applications.
Speaker: Tomasz Choma
Date: Tuesday, March 17, 2026
Time: 4:10 PM – 4:40 PM
Location: Room 21
Laser Ultrasonic Atomization
Standard atomization techniques often face limitations based on their heat sources – induction heating is typically restricted to non-refractory metals, while plasma sources can offer limited thermal control for volatile elements. We will present a novel approach combining laser melting with ultrasonic atomization. This method allows for precise heat input, enabling the processing of both high-melting-point refractory metals and functional materials containing volatile components.
Speaker: Łukasz Żrodowski
Date: Wednesday, March 18, 2026
Time: 10:20 AM – 10:40 AM
Location: Room 21
IN ALLOY DEVELOPMENT
Ai-Driven Atomization
This year, AMAZEMET is focusing on a significant advancement to our rePOWDER platform: a new, integrated system for AI-Driven Process Automation. This upgrade integrates a proprietary Ai-Vision model to enable fully autonomous process management for alloy development and powder production.
Using real-time visual analysis, the system monitors the material on the sonotrode, feeding rate, and the atomization process itself. This development allows for experienced operator-level efficiency and continuous operation for extended periods, enabling a single operator to supervise multiple machines.
Remote Operation and API Integrations
Dedicated API enables integration with industrial networks (MES/ERP), remote process control, comprehensive supervision (including camera feed access), and centralized data logging.
Edge Ai Computing
Contains a dedicated, industrial-grade GPU to execute the Ai model in real-time, ensuring minimal latency (approx. 120 ms) and rapid process adjustments.
New Custom Plasma Source
Plasma Source Integrates a new, custom plasma source, optimized for the rePOWDER platform and engineered for high reliability and overload resistance.
Integrated Recirculation System
This new design integrates the recirculation system directly into the cabinet structure, reducing the total platform width by 68 cm, and making its footprint even more lab-friendly.
Passivation & Filter Cleaning
Improved filter cleaning procedure which now includes a passivation cycle, extending component life and maintaining system purity.
Ai-Vision Control
Executes continuous, real-time positional adjustments based on the real-time Ai’s visual analysis of the melt pool via industrial-grade camera.
Process Parameter Control
Autonomously modulates plasma current, ultrasonic power, and gas flow. The system will, for example, pause wire feeding if it detects poor material wettability or overfeed of atomized material.
Intelligent Sequences
Executes complex, automated sequences, including sonotrode scanning, oxygen level verification, and arc start/stop protocols.
Manual Override & Alarms
The operator can also manually intervene or pause the autonomous process at any time. Process alarms will automatically interrupt any sequence.
Automated Self-Cleaning
Initiates a self-cleaning procedure using a dedicated gas blower to clear process buildup from the sonotrode, minimizing downtime.
Precision Delivery
Ensures high-accuracy, stable feedstock delivery, which is critical for maintaining melt pool consistency.
Consumption Monitoring
Provides precise tracking of material usage for process documentation.
Dynamic Feed Rate
The material feed speed is automatically adjusted in real-time to match process demands.
High Stability Feedstock Delivery
Ensures accuracy and stability in feedstock delivery.
LASER MELTING SOURCE
AMAZEMET has announced the development of a new high-energy laser source. This latest innovation, developed under the EU-funded project aims at enabling next-level efficiency and purity for ultrasonic atomization process.
Compared to conventional TIG or plasma-based melting systems, the laser-based energy source provides a highly concentrated and cleaner heat source that ensures more efficient atomization of high-performance materials. The new melting source will seamlessly integrate into the rePOWDER atomization platform, further strengthening AMAZEMET’s position at the forefront of metal powder processing technologies.
1
EXPANDED MATERIAL RANGE
The high-intensity laser enables the atomization of a broad range of materials, from lightweight aluminum to high-melting-point metals like titanium and niobium.
2
CLEANER AND MOrE PRECISE MELTING
The process eliminates the need for consumable electrodes found in TIG and plasma torches, avoiding tungsten contamination and minimizing undesired element evaporation.
3
IMPROVED POWDER QUALITY
By eliminating contamination risks associated with traditional plasma sources, we achieve cleaner, more controlled atomization with improved powder quality.
4
INCREASED PROCESS EFFICIENCY
The laser ensures precise energy input on the sonotrode surface, enabling advanced scanning strategies that optimize material melting, enabling the users to from employ expertise from Laser Powder Bed Fusion (L-PBF) and Electron Beam Powder Bed Fusion (EB-PBF).
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ATOMIZATION SERVICES
ON-DEMAND
At AMAZEMET, we produce high-quality metal powders using advanced ultrasonic atomization technology. It allows us to create cutom powders with superior characteristics, ensuring optimal performance in your applications. Our process offers:
- Narrow Particle Size Distribution:
Ensuring precision and uniformity. - Near-Perfect Sphericity: Enhancing flowability and packing density.
- Satellite-Free Powders: Delivering clean surfaces without unwanted particles.
- Unoxidized Surfaces: Achieved through high purity process atmosphere.
- Low Inert Gas Consumption: minimizing costs of atomization.
Atomization Service by AMAZEMET includes:
- Low Barrier to Entry
- High Process Efficiency
- Customized Material Capability
- Unique Recycling Options
- Pre-Alloying Service
- Multi-Material Orders
AMAZEMET commits to full transparency by sharing all relevant processing parameters with the client. The company’s application team, consisting of materials science experts (PhDs and PhD candidates), will also provide support in preparing research papers.
SCHEDULE A MEEETING AT TMS 2026
To schedule a dedicated meeting with our Application Engineers at Booth 419, San Diego Convention Center, please use the links below:
