PyroGenesis Canada Inc. has been granted a U.S. patent for its NexGen plasma atomization technology, marking a notable development in metal powder production for additive manufacturing. The patent, U.S. Patent No. US 11839918, focuses on a method for producing high-purity spherical metallic powders at elevated production rates using one or two wire feeds.
This technology diverges from traditional plasma atomization by employing a dual-wire feed system, where the wires are electrically charged before plasma atomization. This process is more efficient, leading to higher production rates and a narrower particle size distribution, enhancing uniformity and consistency.
“The NexGen process is a significant departure from conventional plasma atomization, as the improved efficiency from NexGen not only targets higher production rates, but also narrower particle size distribution for more uniformity and consistency, and an ability to tailor particle size distribution (“PSD”) to customer requirements,” said Pierre Carabin, PyroGenesis’ CTO and Chief Strategist.
The system’s single-plasma-torch design aligns with the company’s commodity security and optimization strategy, promising customers denser, more spherical powders with higher yield and reduced waste. This approach also contributes to energy efficiency, supporting customers in reducing their carbon footprint and achieving Scope 3 emissions targets.
Traditional plasma atomization methods, typically less efficient, are challenged by the NexGen system’s innovative approach. This system uses two metal wire spools, such as titanium, that are electrically charged to create an arc that melts the wire. The melted wire is then atomized into powder particles using a supersonic plasma stream, resulting in more efficient metal atomization and increased production output.
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PyroGenesis has now fully commercialized its NexGen system and entered the titanium metal powders market. The company’s development of high-quality titanium metal powders is part of a broader strategy to enhance the availability of critical minerals and optimize production processes. The company, known for its advanced plasma processes and sustainable solutions, continues to lead in several key industry sectors.
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