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

Controlled Metal Powder Classification for Consistent Additive Manufacturing

Producing high-quality metal powders for additive manufacturing requires precise control over particle size, cleanliness, flowability, and consistency. Following atomization, metal powders contain a broad range of particle sizes that must be accurately separated before they can be used in demanding 3D-printing applications.

This application demonstrates a metal powder classification solution developed by MLT Cuccolini, TIERMAX’s technology partner for industrial sieving and separation systems. The system combines controlled powder handling, multi-stage sieving, and automated process management to prepare metal powders for additive manufacturing applications.

The Challenge

Metal powder produced through gas atomization contains particles across a wide size distribution. This can include oversized particles, ultra-fine material, and intermediate fractions suitable for different additive manufacturing or powder metallurgy applications.

For 3D-printing powders, the required particle-size window can be particularly narrow. Coarse particles above approximately 90 µm may need to be removed, while ultra-fine particles below approximately 10–20 µm may also need to be separated.

The process therefore requires a system capable of:

• Achieving precise particle-size classification
• Separating multiple powder fractions consistently
• Maintaining good powder flowability and apparent density
• Minimizing mesh blinding at fine separation points
• Containing fine metallic powders safely
• Reducing manual handling throughout the process

The Solution

MLT Cuccolini developed a classification system based on its circular vibrating sieves, designed for challenging fine-powder separation.

Installed downstream of the atomization and intermediate powder-handling stages, the sieving system separates the incoming material into oversize, specification-compliant, and fine fractions according to the required particle-size range.

Multi-deck configurations can perform several separation stages in a single process, while controlled multifrequency vibration supports efficient screening at fine cut points and helps reduce mesh blinding.

For complete powder handling, the sieving equipment can be integrated with:

• Bin unloading systems
• Controlled feeding equipment
• Multi-stage classification
• Dedicated collection bins
• Powder transfer connections
• Centralized process controls

Where required, the complete process can also operate under inert gas conditions, incorporating suitable sealing, gas management, and monitoring to support safe handling and protect powder quality.

Automated Process Control

The integrated system can be managed through a centralized control panel coordinating material flow, sieving parameters, and safety functions.

Recipe management enables the system to accommodate different powder grades, while process monitoring and data collection help maintain repeatable operating conditions.

Quick-connect bin interfaces further simplify powder transfer and reduce unnecessary operator interaction with fine metal powders.

The Result

The classification process provides controlled and repeatable particle-size distribution for metal powders used in additive manufacturing.

Accurate removal of oversized and ultra-fine particles helps support:

• Consistent powder flowability
• Stable powder deposition during printing
• Controlled particle-size distribution
• Reduced unwanted fine material
• Repeatable powder quality
• Safer and more contained powder handling

The flexible system configuration also allows producers to adapt the process for different powder grades and production requirements.

The technology can be applied to a range of additive manufacturing powders.

Through our partnership with MLT Cuccolini, TIERMAX provides access to advanced sieving and classification technologies for metal powder production, recovery, and additive manufacturing applications across North America.