Metal additive manufacturing (AM) continues to evolve rapidly, and one of the most important enablers of this progress is the quality of metal powders. Among the various production routes, Vacuum Inert Gas Atomisation (VIGA) has emerged as a cornerstone technology for producing high-purity powders tailored for advanced AM processes. Recent developments across materials science, process engineering, and industrial adoption are pushing the boundaries of what VIGA-based powders can achieve.
VIGA: The Gold Standard for High-Quality Powders
VIGA remains a critical technology because it produces high-purity, spherical powders with tightly controlled chemistry and particle size distribution, key requirements for processes like laser powder bed fusion (LPBF) and electron beam melting (EBM).
Recent improvements in VIGA systems include:
- Better vacuum control → reduced oxygen and nitrogen contamination
- Advanced nozzle and gas-flow designs → improved sphericity and yield
- Flexible batch sizes → from R&D-scale to industrial production
These refinements are enabling more consistent powder quality, which directly translates into improved part performance and repeatability in AM.
Expansion of Alloy Development
One of the biggest trends is the rapid expansion of AM-specific alloys produced via VIGA.
New and optimised materials include:
- Nickel-based superalloys for aerospace
- Cobalt-chrome (CoCrMo) for medical and high-temperature applications
- Advanced steels and iron-based alloys
- Reactive metals (e.g., titanium alloys) with tighter impurity control
For example, newly introduced CoCrMo powders are being engineered for high stiffness, wear resistance, and elevated-temperature performance, targeting critical aerospace components.
What’s new:
Rather than adapting traditional alloys, manufacturers are now designing “AM-first” compositions, optimised for:
- Melt pool stability
- Reduced cracking
- Better printability and microstructure control
Surface Engineering of Powders
A major innovation area is engineering the surface of VIGA powders, not just their composition.
Recent research shows that nanotextured powder surfaces can significantly improve laser absorption, by up to ~70% in some metals.
Why this matters:
- Improved energy efficiency during printing
- Better processing of difficult materials like copper and tungsten
- Higher density parts at lower laser power
This represents a shift from “powder as feedstock” to powder as an engineered functional material.
Finer Powders and Improved Flowability
AM is moving toward finer particle sizes (≤20 µm) to enable:
- Higher resolution prints
- Thinner layers
- Improved surface finish
However, finer powders introduce cohesion and flow challenges. New solutions include:
- Modified atomisation strategies
- Post-processing treatments to improve flow
- Machine innovations such as advanced coating systems
Emerging techniques (e.g., oscillatory spreading mechanisms) show promise in achieving dense, uniform powder layers even with highly cohesive powders.
Integration of Powder Production and AM Supply Chains
Another major trend is vertical integration, companies are combining metallurgy expertise with powder production and AM.
- Traditional forging and metallurgical firms are entering powder production
- New VIGA facilities are being commissioned globally
- End-to-end control (ingot → melt → powder → print) is becoming a competitive advantage
For instance, new VIGA-based production plants are being established to scale supply for aerospace and industrial AM applications.
Industrialisation and Mass Production
Metal AM is transitioning from prototyping to true industrial-scale manufacturing.
A notable milestone is the adoption of powder-based AM in consumer electronics manufacturing, where titanium components are now being produced in large volumes using fine metal powders.
Key implications:
- Demand for consistent, high-volume VIGA powders is rising
- Powder recyclability and lifecycle management are becoming critical
- Cost reduction through scale is accelerating adoption
Sustainability and Circular Powder Use
Sustainability is becoming central to AM powder development:
- Recycling of unused powder in AM builds
- Use of recycled feedstock in atomisation
- Reduction of material waste compared to subtractive manufacturing
Industrial users are demonstrating significant raw material savings through powder-based AM, reinforcing its environmental advantages.
Digitalisation and Process Control
Advanced modelling and digital tools are now being applied to:
- Predict powder behaviour during spreading and melting
- Optimise atomisation parameters in VIGA systems
- Control defects and variability in AM builds
This is enabling data-driven powder design, linking:
atomisation → powder properties → printing behaviour → final part performance
Market Growth and Strategic Importance
The VIGA market itself is expanding steadily, driven by AM demand:
- Estimated at hundreds of millions of dollars globally
- Continued growth expected through the next decade
This reflects the increasing recognition that:
Powder quality is the foundation of reliable metal additive manufacturing
Conclusion
The latest developments in metal additive manufacturing using VIGA-derived powders point to a clear shift:
From:
- Generic powders
- Prototype-scale production
- Trial-and-error processing
To:
- Engineered powders with tailored surfaces and compositions
- Industrial-scale, vertically integrated supply chains
- Data-driven optimisation of the entire AM ecosystem
VIGA systems remain at the heart of this transformation, evolving from a powder production method into a strategic enabler of next-generation manufacturing. Looking to enhance your powder production? Contact PSI today, to discuss your plant requirements.