Atomizing Metal Powder Market Size and Share
Market Overview
| Study Period | 2019 - 2030 |
|---|---|
| Market Size (2025) | USD 3.12 Billion |
| Market Size (2030) | USD 4.29 Billion |
| Growth Rate (2025 - 2030) | 6.56% CAGR |
| Fastest Growing Market | Asia Pacific |
| Largest Market | Asia Pacific |
| Market Concentration | Medium |
Major Players
*Disclaimer: Major Players sorted in no particular order Image © Mordor Intelligence. Reuse requires attribution under CC BY 4.0. |
|
Atomizing Metal Powder Market Analysis by Mordor Intelligence
The Atomizing Metal Powder Market size is estimated at USD 3.12 billion in 2025, and is expected to reach USD 4.29 billion by 2030, at a CAGR of 6.56% during the forecast period (2025-2030). Growth is powered by decentralized production models, a sharp pivot toward ultra-high-purity grades, and rising aerospace and electric-vehicle demand. Gas atomization retains scale advantages, but plasma atomization gains ground as turbine builders demand sub-10 ppm oxygen levels. Titanium and nickel superalloy powders record the fastest uptake as powder metallurgy allows near-net-shape parts that avoid segregation seen in ingot routes. Asia-Pacific dominates both consumption and capacity additions, supported by Chinese self-reliance programs and India’s cost-competitive supply base. Mid-level fragmentation prevails: incumbents such as Höganäs and Sandvik leverage integrated supply chains, while challengers deploy novel ultrasonic and mechanical atomization concepts to cut energy use and cycle times.
Key Report Takeaways
- By the atomization process, gas atomization commanded 56.67% of the atomizing metal powder market share in 2024, while plasma atomization is projected to grow at a 6.98% CAGR through 2030.
- By metal type, stainless steel held 29.56% of the atomizing metal powder market size in 2024, whereas titanium and superalloy powders are forecast to accelerate at a 7.02% CAGR to 2030.
- By application, additive manufacturing led with 40.23% revenue share in 2024, and is expected to post the highest 6.45% CAGR during 2025-2030.
- By end-user industry, aerospace and defense accounted for a 32.89% share of the atomizing metal powder market size in 2024, and automotive and EV manufacturing are growing at a CAGR of 6.90%.
- By geography, Asia-Pacific captured 38.45% of the atomizing metal powder market share in 2024 and is forecast to expand at a 7.06% CAGR to 2030.
Global Atomizing Metal Powder Market Trends and Insights
Driver Impact Analysis
| Drivers | (~) % Impact on CAGR Forecast | Geographic Relevance | Impact Timeline |
|---|---|---|---|
| Rapid growth in additive manufacturing | +1.8% | Global, APAC lead | Medium term (2-4 years) |
| Demand for high-performance PM parts | +1.5% | North America and Europe core, APAC emerging | Long term (≥ 4 years) |
| Need for advanced alloys | +1.2% | Global, aerospace hubs | Medium term (2-4 years) |
| Shift to decentralized micro-atomization | +0.9% | North America and EU early, APAC scaling | Long term (≥ 4 years) |
| Ultra-low-oxygen powders for hydrogen energy | +0.7% | Global, EU hydrogen initiatives | Long term (≥ 4 years) |
| Source: Mordor Intelligence | |||
Rapid Growth in Additive Manufacturing (Metal 3D Printing)
Desktop metal binder-jet platforms now certify recycled superalloys, signaling a pivot toward circular feedstocks and tightening powder re-use protocols. Recycled powders must retain morphology and chemistry through up to 38 reuse cycles, and in-line characterization technologies track oxidation states in real time. With unfused material representing up to 80% of build volume, recyclability directly affects cost curves. The trend drives suppliers to guarantee powder lot consistency across varying melt chemistries, favoring those with robust statistical process controls.
Increased Demand for High-Performance Powder-Metallurgy Parts in Aerospace and Automotive
Boeing’s approval of elemental-blend sintered titanium widens PM’s footprint from niche to mainstream aircraft structures. Material utilization rises by 55%, shrinking billet waste streams. EV motor programs mirror this logic: iron-silicon powders yield soft-magnetic rotors that achieve higher torque density than stamped laminations while trimming machining steps. Cross-industry harmonization of specifications lowers per-kilogram prices and accelerates adoption.
Surging Need for Advanced Alloys (Super-, Ti- and Ni-Based)
Elevated turbine inlet temperatures demand alloys such as Rene 95 that crack during hot-working yet flow readily in powder bed fusion. Plasma atomization offers contamination control essential for fatigue-critical rotating parts. Coarse Ti64 fractions support thicker layers, reducing build times without sacrificing static strength. As recycling technologies mature, scrap turnings become feedstock, alleviating raw titanium cost pressures.
Shift Toward Decentralized Micro-Atomization Units for On-Demand Production
Mechanical powder methods convert barstock into flowable feedstock without melting, enabling localized supply next to machine shops and lowering carbon intensity. Ultrasonic atomization research funded by the U.S. Department of Energy shows vibration-induced droplet ejection for diverse alloys, unlocking batch sizes suited to prototyping and repair tasks. Distributed capacity mitigates geopolitical shipment risks and speeds alloy innovation cycles.
Restraint Impact Analysis
| Restraints | (~) % Impact on CAGR Forecast | Geographic Relevance | Impact Timeline |
|---|---|---|---|
| High production cost and energy intensity of atomization | -1.1% | Global, particularly affecting smaller players | Short term (≤ 2 years) |
| Stringent quality-control requirements (PSD, morphology, flow) | -0.8% | North America and EU regulatory focus | Medium term (2-4 years) |
| Volatility in helium supply and pricing for plasma/gas atomization | -0.7% | Global, with acute impact on plasma atomization users | Short term (≤ 2 years) |
| Limited recycling loops for reactive/critical metal powders | -0.5% | APAC and North America manufacturing hubs | Long term (≥ 4 years) |
| Source: Mordor Intelligence | |||
High Production Cost and Energy Intensity of Atomization
Helium gas atomization proves energy-efficient but helium supply remains linked to declining natural-gas extraction, exposing producers to price spikes. Plasma and mechanical routes cut kilowatt-hours per kilogram by eliminating melt superheat or recovering process heat. VDM Metals’ vacuum inert gas plant illustrates capex necessary to balance efficiency with purity, a hurdle for smaller entrants
Stringent Quality-Control Requirements (PSD, Morphology, Flow)
Aerospace, medical, and spaceflight verticals adopt NASA MSFC and MPIF standards that stipulate in-process monitoring and statistical control of powder lots[1]NASA, “MSFC Technical Standard for Laser-Powder Bed Fusion,” nasa.gov. Compliance entails laser diffraction, rheological analysis, and SEM imaging capacity, adding fixed cost burdens. Recyclate qualification intensifies testing frequency, favoring vertically integrated suppliers with laboratory infrastructure[2]Metal Powder Industries Federation, “Powder Characterization Standards,” mpif.org .
Segment Analysis
By Atomization Process: Plasma Technology Gains Momentum
The atomizing metal powder market size for plasma atomization is expanding faster than any other process, clocking a 6.98% CAGR as end users seek oxygen levels under 30 ppm for hydrogen-ready turbines. Gas atomization still fills high-volume orders thanks to established furnaces, yet its 56.67% 2024 atomizing metal powder market share masks purity ceilings that constrain future aerospace grades. Water atomization satisfies cost-driven applications such as welding additives, while centrifugal and ultrasonic processes remain niche, tailored to refractory metals that cannot contact water or oxide-forming atmospheres.
Improved plasma torch stability and scalable powder catchment systems elevate throughput, narrowing the cost gap with gas routes. Firms such as PyroGenesis deploy modular plasma nozzles capable of 150 kg h-1, broadening alloy coverage from Ti64 to nickel superalloys. Ultrasonic atomization, supported by U.S. federal grants, shows promise in lab-scale demonstrations, converting irregular scrap pieces into spheroidal shots suitable for binder jet platforms.
Note: Segment shares of all individual segments available upon report purchase
By Metal Type: Titanium Superalloys Lead Growth
Stainless steel dominates 2024 volume with a 29.56% share, but titanium and nickel superalloys deliver the strongest upside at 7.02% CAGR. Advanced airframe and turbine projects push demand for Ti-6Al-4V and γ′-strengthened Ni alloys, whose segregation issues render ingot forging unviable. Powder routes enable fine-grain control and isotropic mechanical properties. Quest Metals’ recycling of aerospace Ti scrap, combined with plasma atomization, adds secondary feedstreams that temper raw-material price volatility.
Aluminum powder receives a lift from lightweight battery enclosures, while copper powders power heat sinks and e-mobility bus bars. Refractory-metal demand rises within fusion energy prototypes. Powder metallurgy facilitates gradient architectures, combining heat-resistant cores with conductive skins, giving OEMs new design freedom.
By Application: Manufacturing Diversification Accelerates
Additive manufacturing retains a leading 40.23% share and continues a 6.45% growth path as serial production accelerates in orthopedic, aerospace bracketry, and RF shield housings. Yet automotive electrification displaces prototyping volume with functional parts: stator segments, differential gears, and bipolar plates now specify sintered iron-silicon or stainless steel powders due to their magnetic and corrosion-resistance profiles.
Powder-metallurgy components outside AM, hiper-cooled turbo housings, valve seats, and exhaust flanges, extend adoption, leveraging 99% material yield versus subtractive machining. Cutting tools embrace nano-carbide dispersion achievable only through hot isostatic pressing of blended powders. Thermal-spray feedstock benefits from plasma spheroidization that tailors density and flowability, boosting coating adhesion
By End-User Industry: Automotive Electrification Drives Growth
Aerospace and defense remain the volume anchor with a 32.89% 2024 stake, yet the auto and EV sector advances fastest at 6.90% CAGR. Electrified powertrains require rotor and stator lamination alternatives that blend soft magnetism and structural integrity, attributes delivered by sintered iron-silicon powders. Powder metallurgy underpins lightweight crash structures through aluminum foam cores encapsulated in conventionally formed skins.
Medical device OEMs transition hip cups and spinal cages to lattice-filled geometries printed from Ti64, lowering elastic modulus closer to cortical bone. Engineering builders specify PM gears and cams for oil-free compressors, cutting maintenance costs. Energy companies order ultra-clean nickel powders for hydrogen turbine blades, tying materials supply directly to decarbonization roadmaps.
Note: Segment shares of all individual segments available upon report purchase
Geography Analysis
Asia-Pacific leads the atomizing metal powder market with 38.45% share and accelerates at 7.06% CAGR as China commissions new gas and plasma lines to reduce import dependency on aerospace-grade powders. Provincial subsidies offset start-up capital, while military-civil fusion policies guarantee baseline demand. India’s Tier-2 suppliers win long-term agreements to produce Ti64 components for global OEMs, establishing local powder sourcing for feedstock security.
North America leverages public-private funding: a USD 23.4 million Department of Defense grant to 6K Additive scales upcycling of critical metals for hypersonic programs. Europe focuses on green metallurgy, with VDM Metals bringing a vacuum inert-gas atomizer online in Germany to cut indirect emissions through renewable power use.
South America intensifies iron-ore value-addition via powder plants in Brazil, while Middle East oil producers source nickel alloy powders for sour-gas service valves as they diversify into downstream manufacturing.
Competitive Landscape
The market exhibits moderate fragmentation. Sandvik’s 50-year experience in gas atomization underpins a reputation for batch-to-batch homogeneity, securing framework deals with aerospace primes. Disruptors differentiate through technology: PyroGenesis offers plasma torches scaling above 100 kg h-1. Metal Powder Works uses mechanical shear to generate powders straight from barstock, reducing energy by eliminating melting. Patent filings concentrate on ultrasonic nozzle designs and machine-learning-driven in-process monitoring, signaling competition will hinge on energy intensity and quality assurance rather than capacity alone.
Atomizing Metal Powder Industry Leaders
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CRS Holdings, LLC
-
General Electric Company
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Höganäs
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Sandvik AB
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Oerlikon Management AG
- *Disclaimer: Major Players sorted in no particular order
Recent Industry Developments
- September 2024: Tekna introduced advanced Ti64 coarse powders optimized for laser powder-bed fusion, enabling 60 µm to 90 µm layers while preserving mechanical strength.
- November 2023: 6K Additive acquired Global Metal Powders, expanding its upcycling footprint and securing additional capacity for aerospace and defense powders.
Global Atomizing Metal Powder Market Report Scope
| Gas Atomization |
| Plasma Atomization |
| Water Atomization |
| Centrifugal Atomization |
| Other Methods (e.g., ultrasonic) |
| Stainless Steel Powders |
| Titanium and Superalloy Powders |
| Aluminum Powders |
| Copper and Copper-Alloy Powders |
| Nickel-based Alloys |
| Other Metals and Alloys |
| Additive Manufacturing (AM/3DP) |
| Powder-Metallurgy Components/Parts |
| Cutting Tools and Wear Parts |
| Coatings and Thermal-Spray Materials |
| Other Industrial Applications |
| Aerospace and Defense |
| Automotive and EV Manufacturing |
| Medical and Dental Devices |
| Industrial Machinery and Tooling |
| Energy (turbines, oil and gas) |
| Other End-user Industries |
| Asia-Pacific | China |
| India | |
| Japan | |
| South Korea | |
| ASEAN Countries | |
| Rest of Asia-Pacific | |
| North America | United States |
| Canada | |
| Mexico | |
| Europe | Germany |
| United Kingdom | |
| France | |
| Italy | |
| Spain | |
| Russia | |
| NORDIC Countries | |
| Rest of Europe | |
| South America | Brazil |
| Argentina | |
| Rest of South America | |
| Middle-East and Africa | Saudi Arabia |
| United Arab Emirates | |
| South Africa | |
| Rest of Middle-East and Africa |
| By Atomization Process | Gas Atomization | |
| Plasma Atomization | ||
| Water Atomization | ||
| Centrifugal Atomization | ||
| Other Methods (e.g., ultrasonic) | ||
| By Metal Type | Stainless Steel Powders | |
| Titanium and Superalloy Powders | ||
| Aluminum Powders | ||
| Copper and Copper-Alloy Powders | ||
| Nickel-based Alloys | ||
| Other Metals and Alloys | ||
| By Application | Additive Manufacturing (AM/3DP) | |
| Powder-Metallurgy Components/Parts | ||
| Cutting Tools and Wear Parts | ||
| Coatings and Thermal-Spray Materials | ||
| Other Industrial Applications | ||
| By End-user Industry | Aerospace and Defense | |
| Automotive and EV Manufacturing | ||
| Medical and Dental Devices | ||
| Industrial Machinery and Tooling | ||
| Energy (turbines, oil and gas) | ||
| Other End-user Industries | ||
| By Geography | Asia-Pacific | China |
| India | ||
| Japan | ||
| South Korea | ||
| ASEAN Countries | ||
| Rest of Asia-Pacific | ||
| North America | United States | |
| Canada | ||
| Mexico | ||
| Europe | Germany | |
| United Kingdom | ||
| France | ||
| Italy | ||
| Spain | ||
| Russia | ||
| NORDIC Countries | ||
| Rest of Europe | ||
| South America | Brazil | |
| Argentina | ||
| Rest of South America | ||
| Middle-East and Africa | Saudi Arabia | |
| United Arab Emirates | ||
| South Africa | ||
| Rest of Middle-East and Africa | ||
Key Questions Answered in the Report
What is the current value of the atomizing metal powder market?
The atomizing metal powder market size is USD 3.12 billion in 2025 and is projected to reach USD 4.29 billion by 2030.
Which atomization process is growing fastest?
Plasma atomization registers the highest growth, advancing at a 6.98% CAGR as aerospace and hydrogen-energy applications require ultra-low-oxygen powders.
Why are titanium and superalloy powders in high demand?
Aerospace and defense programs need powders that achieve fine, segregation-free microstructures for high-temperature parts, pushing titanium and nickel superalloy volumes up at a 7.02% CAGR.
How does additive manufacturing influence powder demand?
Additive manufacturing captures 40.23% of powder revenue and shifts specifications toward consistent morphology and recyclability, driving investments in in-process monitoring.
Which region leads consumption and capacity?
Asia-Pacific holds 38.45% market share and is the fastest-growing region due to Chinese self-sufficiency programs and India’s expanding aerospace supply chain.
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