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Tags: additive manufacturing
The patent describes the innovative aspects of the Nexgen system that have the potential to create higher and more efficient productivity.
the patent describes the innovative aspects of the nexgen system that create the potential for higher and more efficient production rates
Pyrogenesis Canada Inc., a high-tech company that designs, develops, manufactures and commercializes advanced plasma processes and sustainable solutions to reduce greenhouse gases (GHGs) and address environmental pollutants, has been granted a patent (US11839918) for Nexgen plasma atomized powders by the United States Patent and Trademark Office (USPTO).
pyrogenesis canada inc., a high-tech companythat designs, develops, manufactures, and commercializes advanced plasma processes and sustainable solutions that are geared to reduce greenhouse gases (ghg) and address environmental pollutants, has been awarded a patent (us 11839918) from the united states patent and trademark office (uspto)for its nexgen plasma atomization powder.
The U.S. patent, titled "Method and apparatus for producing high-purity spherical metal powders from one or two wires at high productivity," describes the company's Nexgen plasma atomization technology for the production of metal powders used in additive manufacturing. In particular, the patent describes innovative aspects of the NEXGEN system that create the potential for higher and more efficient productivity, including a two-wire simultaneous feeding method in which the wire itself is charged before reaching the plasma atomization step.
this us patent, titled, “method and apparatus for producing high purity spherical metallic powders at high production rates from one or two wires”, describes the company’s nexgen plasma atomization technology for producing metal powder for use in additive manufacturing. in particular, the patent describes the innovative aspects of the nexgen system that create the potential for higher and more efficient production rates, including a two-wire simultaneous feedstock approach where the wires themselves are electrically charged prior to reaching the plasma atomization step.
Pierre Carabin, CTO and Chief Strategist at Pyrogenesis and co-inventor of the technology, said: "The Nexgen process is significantly different from conventional plasma atomization because the efficiency increased by Nexgen is not only for higher productivity, but also for narrower particle size distributions for more uniformity and consistency, with the ability to tailor particle size distributions (PSDs) to customer requirements. "For Pyrogenesis, this means producing more powder with just one plasma torch in one system, in line with our commodity safety and optimization business strategy. For our customers, this means they can get the best, most spherically consistent, densest powder from typical plasma atomization, but with the added benefit of buying from North America**, it can provide higher yields and less waste of recognized critical minerals, while also being more energy efficient, helping them reduce their carbon footprint and meet their Scope 3 emissions targets. ”
the nexgen process is a significant departure from conventional plasma atomization, as the improved efficiency from nexgen not only targets higher production rates, but also narrower particle size distribution for more uniformity and consistency, and an ability to tailor particle size distribution (psd) to customer requirements,” said pierre carabin, chief technology officer and chief strategist at pyrogenesis, and the co-inventor of the technology.
for pyrogenesis, that means producing more powder in a single system and with only a single plasma torch – in accordance with our commodity security and optimization business strategy. for our customers, that means they receive the finest, most spherically-consistent, and densest powders from typical plasma atomization, but with the added benefits of buying from a north american-based source that offers higher yield and less waste of a recognized critical mineral, while also being more energy efficient – helping them to reduce their carbon footprint and meet their scope 3 emissions targets.”
The main disadvantage of conventional plasma atomization – the use of a single wire fed centrally through a plasma torch or the use of three plasma torches aligned to a centrally positioned wire – is that it is relatively less productive compared to water and gas atomization, which is a very energy-efficient process.
traditional plasma atomization – using either a single wire centrally fed through a plasma torch, or three plasma torches aiming at one centrally-positioned wire – has the primary disadvantage of h**ing a relatively low production rate in comparison to water and gas atomization, because plasma atomization is a very energetically inefficient process.
To solve this problem, the Pyrogenesis Additive's Nexgen system powers two separate reels of wire (such as titanium) that are first charged, creating an arc to melt the wire, and then the plasma torch uses a stream of supersonic plasma to atomize the melted wire into powder particles. This makes the atomization of the metal more efficient, resulting in a significant increase in yield.
to combat this, pyrogenesis additive’s nexgen system feeds two separate spools of metal wire (such as titanium) that are first electrically charged, creating an electrical arc that melts the wire before a plasma torch atomizes the melted wire into powder particles using a supersonic plasma stream. this results in a more efficient atomization of the metal – raising production output significantly.
Massimo Dattilo, Vice President of Pyrogenesis Additive, said: "Plasma atomization is considered the standard for the production of additive manufacturing powders. ”。Pyrogenesis not only invented the process, but also the name, which is now widely used in the industry. Due to our commitment to continuous improvement, when we decided to re-enter the market, we were tasked with taking plasma atomization to the next level with a redesigned system we named "Nexgen". The confirmation of this U.S. patent from Nexgen is a key validation of our approach and another major issue we checked during our re-entry to market. ”
plasma atomization is considered the gold standard for the production of additive manufacturing powder,” said massimo dattilo, vice president of pyrogenesis additive. “pyrogenesis not only invented the process, but coined the name, which is now widely used in the industry. because of our dedication to continuous improvement, when we decided to re-enter the market, we did so with a mandate to advance plasma atomization to the next level through a redesigned system we named “nexgen”. the confirmation of this us patent for nexgen is a key validation of our approach and another major box checked in our market re-entry progress.”
The Company has patent applications for the same Nexgen plasma atomization process in Canada and other global jurisdictions.
the company has patents pending in canada and other global jurisdictions for the same nexgen plasma atomization process.
Dattilo adds: "Nexgen's efficiency has increased dramatically, changing the particle size distribution in our production process, which means that we produce a larger average amount of fine powder per production that also includes fine powders in the 5 m to 20 m range for binder jetting and metal injection molding (MIM). We believe that MIM is a key market for the future, in addition to the fine powders we can provide for laser bed applications, as more and more companies, especially consumer electronics companies, continue to switch from stainless steel to titanium to achieve weight and corrosion reduction. ”
the substantially improved efficiency of nexgen, which has shifted the particle size distribution of our production runs, means the larger **erage amount of finer cut powder we can produce per run also includes fine powders in the 5μm – 20μm range suitable for use in binder jetting and metal injection molding (mim). we see mim – in addition to the fine powders we can offer for laser bed applications – as a key market ahead, as more companies especially in consumer electronics continue to move from stainless steel to titanium to achieve weight and corrosion reduction,” added dattilo.
After several years of R&D, the company recently achieved full commercialization and entered the titanium powder market for the first time with tonnage commercial orders.
after several years of r&d, the company recently achieved full commercialization and entrance into the titanium metal powders marketplace withits first by-the-ton commercial order.
p."In order to produce the highest quality metal powders in the additive manufacturing industry, Pyrogenesis Additive has taken a cautious, methodical approach over the past few years to design and prepare our new Nexgen plasma atomization process," says Peter Pascali. "With full commercialization and confirmation of a U.S. patent for our technology, we are optimistic about our future where additive manufacturing will have access to a wide variety of metal powder products." ”
with a goal to produce the highest quality metal powders in the additive manufacturing industry, pyrogenesis additive has taken a cautious, methodical approach over the past few years as we designed, then readied, our new nexgen plasma atomization process,” said p. peter pascali, president and ceo pyrogenesis canada inc. “with full commercialization achieved, and now with the us patent confirmed for our technology, we look forward with great optimism regarding our future, with an ever-widening range of metal powder offerings becoming **ailable to the additive manufacturing industry.”
The company's development of high-quality titanium powders is part of its three-tier solution ecosystem, which aligns with key economic drivers for heavy industry worldwide. Metal powders are part of the company's commodity safety and optimization layer, in which viable metals are made and production is optimized to increase yield, helping to maximize raw materials and increase the availability of critical minerals. Canada** and many others** around the world have identified titanium as a critical mineral.
the company’s development of high-quality titanium metal powders is part of its three-tiered solution ecosystem that aligns with economic drivers that are key to global he**y industry. metal powders are part of the company’s commodity security and optimization tier, where the recovery of viable metals, and the optimization of production to increase output, helps to maximize raw materials and improve the **ailability of critical minerals. titanium has been identified as a critical mineral by the canadian government and many other governments worldwide.
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