| Abstract Scope |
Metal powder production for additive manufacturing has long been dominated by melt-based gas atomization, despite its inherent variability in particle morphology, internal porosity, satellites, and chemistry variation. These inconsistencies in gas atomization increasingly limit process stability and efficiency in modern AM. Metal Powder Works’ DirectPowder™ process removes melt-state variability entirely by transforming wrought bar stock into powder through mechanical milling with precision tooling and software control. This room temperature, solid state process preserves the chemistry and properties of the bar feedstock, resulting in fully dense particles of consistent morphology. This presentation will compare DirectPowder™ and gas atomized powders in AM techniques like LPBF and Cold Spray, examining how differences in powder manufacturing and morphology influence flow behavior, spreading uniformity, melt pool stability, and deposition efficiency. By evaluating morphology‑driven process responses across these AM modalities, the session aims to challenge conventional assumptions about the powder characteristics required for additive manufacturing. |