Test samples for atomizer and metal 3D printer

[sgbaird]

Create an in-house formulation for a common alloy and send to Additive Plus to have them atomize with ATO Lab Plus and print a test sample for us with AO A30 300W printer (or 200W would be OK), then send back to us so we can do some mechanical testing (maybe we send sample to PIP folks to get the characterization data for it). Ideally, we'd use the powder dosing equipment at NRC, i.e., the MT system or possibly the autotrickler, depending on the required volume, which we'll need to get from them.

@pranshu-ui could you check with Harry and Ashkhen (with me cc'd) about what would be required to have them run a test sample for us in terms of what minimum volume is required, how we package it, etc.? Sending their emails to you via slack.

We may try for an aluminum alloy of some kind, but it would also be good to get their feedback about a system they think would be a good test case for us.

[pranshu-ui]

Did some background research and sent an email!

[pranshu-ui]

Powder & Atomization

• Material proposal: Aluminum alloy or we recommend starting with a stainless or tool steel such as SS316L, 17-4PH, or 18Ni300 for safety reasons.
• These materials are stable, low-risk, and excellent for a first test run.
• Atomization site: We plan to perform it at our manufacturer’s facility in Poland, using the ATO Lab+ under full process control.
• Lead time: ~4 weeks total (includes setup, atomization, sieving, and packaging).
• Powder quantity: We suggest preparing around 10 kg to have enough for a full build and QA.
• Packaging: Sealed bottles, inert gas backfilled (argon or nitrogen), with full labeling (alloy, batch, PSD, date, net mass).
• MSDS/SDS: We will need the MSDS for any alloy you need to atomize.

Next step: Once you confirm which alloy you prefer, we’ll align dates. The PSD we produce is ideal for Additive Manufacturing by default.

Printing on AO (AO A100, A30 or equivalent)

• Printer used: We’ll use our AO A100, which employs the same laser architecture and optics as the A30 (300 W configuration), ensuring identical process behavior.
• Geometries: We can produce baseline tensile and fatigue coupons (dog-bones, cylinders, or cubes).
• Minimum lot: Preferably 5-8 kg, but we can also run micro-benchmarks with smaller amounts if material is limited.

Observation: You’re welcome to visit our lab during the print to observe and document the process, or we can run it entirely on your behalf and share detailed build data.

Logistics & Test Plan

• Estimated turnaround:
• Atomization → ~6 weeks to 8 weeks
• Printing → ~ 1-2 week
• Shipment → depends on your preferred carrier and location

Shipping of material details: The materials should be shipped to Poland for atomization, if the alloy is aluminum alloy, we are very likely to use Induction Melting system.

Ballpark pricing: Currently being calculated; we’ll share a first estimate once we agree on the quantities of material we need to atomize.

Target schedule: Could you please confirm your desired timeframe for this POC? That will help us plan accordingly.