3D Printing Metal Powder Production – Precision Classification for Additive Manufacturing

Overview

Metal powder for additive manufacturing must meet tight specifications for particle size, cleanliness, flowability and consistency. After gas atomization, powder covers a broad size range that has to be separated accurately before it is fit for demanding 3D printing applications.

This project features a classification system developed by MLT Cuccolini, TiERMAX’s technology partner for industrial sieving and separation. It combines controlled powder handling, multi-stage sieving and automatic process management to prepare metal powder for AM.

The Challenge

Gas-atomized powder includes oversize particles, ultra-fines and intermediate fractions suited to different AM or powder metallurgy uses. For laser powder bed fusion, the window is narrow: particles above about 90 µm may need to be removed, and ultra-fines below about 10–20 µm separated as well. The system had to:

• Classify particle size precisely
• Separate several fractions consistently
• Preserve flowability and apparent density
• Minimize blinding at fine cut points
• Contain fine metal powder safely
• Reduce manual handling

The Solution

The classification system is built on circular vibratory sieves designed for difficult fine-powder separation. Installed after atomization and intermediate handling, it splits incoming powder into oversize, on-spec and fine fractions. Multi-deck machines perform several separations in one pass, while multifrequency vibration keeps fine meshes clear.

For complete handling, the sieves integrate with bin unloading, controlled feeding, dedicated collection bins, powder transfer connections and central controls. Where required, the process runs under inert gas with suitable sealing, gas management and monitoring.

Automated Process Control

A central control panel coordinates material flow, sieving parameters and safety functions. Recipes handle different powder grades, and process monitoring and data logging keep conditions repeatable. Quick-connect bin interfaces simplify transfer and limit operator contact with fine powder.

The Results

• Consistent powder flowability
• Stable powder spreading during printing
• Controlled particle size distribution
• Less unwanted fine material
• Repeatable powder quality
• Safer, contained handling

Through our partnership with MLT Cuccolini, TiERMAX brings these classification and metal powder recovery technologies to powder producers and AM users across the United States.