Centrifugal atomization is an alternative manufacturing method for producing high-quality metal powders designed for additive manufacturing. Unlike gas or plasma atomization, centrifugal systems use a spinning disk to disperse molten metal into fine droplets, which then rapidly solidify into highly spherical, satellite-free particles. This powder exhibits excellent flowability and uniform packing density-key attributes for consistent, high-performance 3D. This presentation outlines the fundamentals of centrifugal atomization and shows real world case studies completed by Innovative Powders. Melts of 1-200 kg are economically feasible with tunable powder size from 25-400 µm produced to date. Key process variables such as disk speed, melt rate, and oxygen free atmosphere will be discussed in, practical terms, highlighting how they control the quality, size and shape of the resulting metal powder. Although Innovative Powders’ atomizer is currently limited to metals with a melt point of ~3000F, future upgrades (Q4/26) will allow refractory metals to be atomized. Case study examples focus on pure copper powders, which are notoriously difficult to produce due to oxidation and wetting issues. These studies show how particle size can be adjusted with process parameters while maintaining excellent morphology. Centrifugal atomization has proven especially effective for these materials, producing spherical particles with low oxygen content and smooth surface topography. Attendees will come away with a clear understanding of what centrifugal atomization is, how it differs from legacy powder-making technologies, and why its unique powder characteristics may enable new opportunities in additive manufacturing.
