Article on Metal Powders in Additive ManufacturingAn informative Article on Metal Powders in Additive Manufacturing:
https://issuu.com/inovar-communications/docs/metal_am_spring_2024_issuu/127?fr=sMDFmMTcyMTYyNjc Metal powders in Additive Manufacturing: An exploration of sustainable production, usage and recycling And PyroGenesis' NexGen Plasma Atomization System has a 2-wire feed (compared to a 1-wire feed). This means that PYR has increased/optimized flow rates in the production of powders (and note that the wire is electrically charged prior to entering the NexGen reactor). Very impressive the technology and solutions that PYR has to offer.
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With full commercialization achieved, and now with the U.S. patent confirmed for our technology, we look forward with great optimism regarding our future, with an ever-widening range of metal powder offerings becoming available to the additive manufacturing industry.”
Great point from @Namazon on PyroGenesis' NexGen Plasma Atomization System:
@Namazon It's a very slick addition to the plasma atomization process they originally invented. No wonder they call it NexGen. The use of an induction coil to essentially melt the titanium (or whatever metal) just prior to being blasted by the plasma into micron spheres. On that patent link that @cargo posted... look at number "14" on the drawing... this is the induction coil... essentially one of these: 
Preheating the titanium means you can run more material in less time compared to a cold feed. I recall Peter saying that the higher the rate of throughput the cheaper it is to produce. Electromagnetic induction heats an electrically conductive object (as in the titanium metal). Eddy currents are generated within the titanium and results in resistive heating. The induction coil can heat the metal to the melting point. Most are made of water-cooled copper rings. They've essentially made an mini induction furnaces add-on that can be used in a vacuum or inert atmosphere. This is cleaner and prevents oxidation. A high frequency magnetic field can actually stir the metal, ensuring consistent alloy distribution. It sounds like a brilliant design. GO PYR GO! And:
“With some traditional metal powder production processes, as the powder is created then filtered and separated into different cut sizes, the fine cut powder is removed for sale, with the remaining coarsest cut often considered of limited use, or even discarded as unsuitable,” said Mr. Massimo Dattilo, VP PyroGenesis Additive. “However, with PyroGenesis Additive’s NexGen™ plasma atomization system, the coarsest cut component of the production batch remains of such a high quality, that we store these powders as inventory for future sales. By selling both the fine and coarse cut of each powder production run, the Company’s yield percentage from raw material is greatly enhanced, which is in line with the Company’s broader mandate for commodity security and optimization.”
“Over the past several years, we designed, then readied, our new NexGen™ plasma atomization process with a goal to produce the highest quality metal powders in the additive manufacturing industry,” added Mr. Pascali. “PyroGenesis Additive has taken a cautious, methodical approach to its new production process. Now, with the full-scale commercialization underway, and a steady influx of initial orders, the long-term conservative strategy that has brought us to this point today is bearing fruit
Very impressive, also the emission reduction side of things here. Also a huge bonus that the NexGen process has almost no waste.