AM PowdersMaterialsMetals

Warsaw University of Technology develops rePowder system for atomizing any metal part or scrap

Stay up to date with everything that is happening in the wonderful world of AM via our LinkedIn community.

Warsaw University of Technology developed a new solution for lowering the costs of using metal powder bed fusion technologies by affordably atomizing any metal part or scrap. The new rePowder system allows users to produce high-quality powder regardless of the initial form of the feed material. Pure elements, previously produced alloys, but also failed printouts, can be thus easily re-pulverized. The full powder production cycle is performed within one device and, in combination with DMLS printers, creates a closed-loop R&D system in line with the basic principles of the circular economy.

rePowder The first to benefit from the new device will be three groups, operating within the faculty, that develop new 3D printed alloys. These are a Biomaterials Group, a Group researching Aerospace Materials and a Structural and Functional Materials Division. “We want the device to serve researchers and promote our technology,” said Łukasz Żrodowski, inventor of the rePowder device and CEO of the Amazemet spin-off that commercializes it.

Today on the market there are several thousand different metallic materials available. However only about 30 of them are used for metal 3D printing. New alloys appear slowly because developing the proper feedstock requires many resources powder to optimize the custom chemical composition. Scientists from the Warsaw University of Technology developed rePowder to address these issues.

Enabling DMLS research

Research on DMLS technology at the Faculty of Materials Science and Engineering started in 2011. “At that time it was a completely new technology in Poland and our first laboratory device, a Realizer SLM 50, was purchased as part of the CePT project,” said Bartłomiej Wysocki PhD, who began his work on metal 3D printing almost 8 years ago. “[…] Since then, we’ve promoted dozens of technologies as part of national strategic projects that we ran in the laboratory. Our work mainly focuses on scaffold materials for bone tissue engineering and regenerative medicine.”

In 2019, the Faculty purchased a new EOS M100 machine, dedicated to the production of materials for aviation and research is currently focused on the production of heat-resistant nickel superalloys. It soon became apparent that DMLS technology can be used to improve material qualities. Not only to manufacture thin-walled cell structures but also for fine-tuning their chemical composition, by carefully controlling oxygen during printing.

“From the very beginning of the laboratory’s operation, we’ve experimented with various titanium alloys, including Ti6Al4V and Ti6Al7Nb, as well as composites based on titanium and ceramics. Since 2014, we have been working on metallic glasses, which ended in their spectacular commercialization by selling the patent application to Heraeus GmBH,” said Bartłomiej Wysocki Ph.D. – supervisor of the biomaterial part of the 3D printing laboratory and CEO of MaterialsCare, which commercializes medical solutions developed in the laboratory.


rePowder for improved metal powders

“Traditional methods of powders production require either high capital expenditure or a multi-stage procedure of forming the material into a wire,” explained Żrodowski. – In both cases, it was not possible to quickly produce a powder suitable for 3D printing on a laboratory scale. Therefore, in 2016, we came up with an idea to create an internally designed device – suited to the technology and the needs of researchers. Instead of producing industrial quantities of materials on large industrial equipment, waiting weeks and paying large sums, scientists can obtain exactly the quantity of material as they need and quickly fine-tune its properties. This will significantly improve their research work.”

“The full use of this effect can be observed in nanocrystalline and amorphous materials – Żrodowski concluded – There are materials with extraordinary properties such as metallic glass from which three-dimensional solid objects are often impossible to produce with other methods. This makes metal 3D printing not only a process of forming a shape, but also the synthesis of materials with improved properties.”


Composites AM 2024

746 composites AM companies individually surveyed and studied. Core composites AM market generated over $785 million in 2023. Market expected to grow to $7.8 billion by 2033 at 25.8% CAGR. This new...

Davide Sher

Since 2002, Davide has built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, he spent 12 years in the United States, where he completed his studies at SUNY USB. As a journalist covering the tech and videogame industry for over 10 years, he began covering the AM industry in 2013, first as an international journalist and subsequently as a market analyst, focusing on the additive manufacturing industry and relative vertical markets. In 2016 he co-founded London-based VoxelMatters. Today the company publishes the leading news and insights websites and, as well as VoxelMatters Directory, the largest global directory of companies in the additive manufacturing industry.

Related Articles

Leave a Reply

Your email address will not be published. Required fields are marked *

Back to top button
Close Popup
Privacy Settings saved!
Privacy Settings

When you visit any web site, it may store or retrieve information on your browser, mostly in the form of cookies. Control your personal Cookie Services here.

These cookies are necessary for the website to function and cannot be switched off in our systems.

Technical Cookies
In order to use this website we use the following technically required cookies
  • wordpress_test_cookie
  • wordpress_logged_in_
  • wordpress_sec

Decline all Services
Accept all Services


Join our 12,000+ Professional community and get weekly AM industry insights straight to your inbox. Our editor-curated newsletter equips executives, engineers, and end-users with crucial updates, helping you stay ahead.