3D Lab receives US patent for ultrasonic atomization method to produce heavy metal powder for AM

Polish additive manufacturing materials specialist 3D Lab has been granted a US patent for its ultrasonic atomization technology designed to produce heavy metal powder for additive manufacturing. The patented method and device address the production of high-quality metal powder, though specific patent number, alloy compositions, and particle size distribution details were not disclosed in the announcement. The company, headquartered in Poland, has been active in metal powder development and now secures intellectual property protection in the US market.

This patent filing sits within a broader industry push to diversify metal powder production methods beyond conventional gas atomization and plasma atomization. Ultrasonic atomization offers potential advantages in particle size control, sphericity, and reduced energy consumption, particularly for refractory and heavy metals that are difficult to process with standard techniques. The development is relevant for metal PBF-LB and binder jetting applications where powder quality directly impacts part density, surface finish, and mechanical properties. However, the technology remains at an early stage relative to established atomization methods from vendors like AP&C, TLS Technik, and Praxair, and the patent grant does not yet indicate commercial-scale production capability.

For 3D Lab, the US patent provides a defensive position but does not by itself constitute a market entry. The company must now demonstrate repeatable powder quality at scale, secure customer qualifications, and build supply agreements before this technology moves from IP portfolio to commercial relevance. Buyers evaluating new powder sources should request batch-to-batch consistency data and independent particle characterization before substituting this material into qualified workflows.