Integrated Metal Powder Granule Production

This process family covers the production and conditioning of high-quality metal granules/powders for powder-based 3D printing and hot isostatic pressing (HIP). The line combines primary particle production with downstream cleaning, classification, degassing and capsule preparation steps required to deliver a stable, application-ready metal powder.

The technological chain begins with the Plasma Rotating Electrode Process (PREP), used for the production of spherical metal granules/powders with low gas porosity and a morphology suitable for demanding downstream applications. This is followed by fraction classification with magnetic separation for controlled particle size distribution and removal of metallic contaminants, electrostatic separation for the dry removal of non-metallic inclusions, and thermovacuum degassing to remove adsorbed moisture and residual gases from the powder surface.

For applications linked to HIP, the process can be extended to a dedicated module for thermovacuum degassing, controlled capsule filling and reliable hermetic sealing. This stage is intended to support the preparation of capsule-packed granules under conditions that are compatible with subsequent densification and consolidation operations.

Each stage may be supplied either as a standalone installation or as part of an integrated full-cycle production line. This modular architecture allows the solution to be adapted to different production scales, alloy systems and plant layouts, while maintaining a single process logic across the entire chain.

In metal additive manufacturing and HIP-related processing, powder quality is not an auxiliary issue – it is one of the foundations of final part quality. Particle shape, cleanliness, internal porosity, moisture content, gas contamination and fraction consistency influence powder handling behavior, feeding stability and the repeatability of subsequent thermal and consolidation operations.

A well-designed production line therefore has to control not only the initial generation of granules, but also the downstream conditioning steps that determine how the metal powder will behave during 3D printing, post-processing and densification. The quality of the starting material contributes directly to structure formation in the metal and, as a result, to the reliability of the finished component.