Induction plasma powder processing is reshaping how industries approach advanced material production. From 3D printing to thermal spraying, this high-temperature, high-purity method delivers powders with unmatched quality.

In our latest PowderTechnology.info monthly poll, we asked:

What do you consider the primary benefit of using induction plasma technology in powder processing?

The responses were clear:

• Production of spherical powders with improved flow properties – 43.75%

• Ability to process high-melting-point materials – 18.75%

• High purity due to lack of electrode contamination – 18.75%

• Versatility in processing metals, ceramics, and more – 18.75%

Let’s explore why these results matter and how they reflect wider trends in the industry.

Induction plasma technology uses radio-frequency (RF) energy to generate a high-temperature plasma without electrodes. This means temperatures of up to 10,000 K can be reached in a controlled, contamination-free environment.

Powders injected into this plasma melt in-flight and solidify into highly spherical particles. The process improves not only flowability and packing density, but also purity and versatility across different materials.

With nearly 44% of respondents choosing spherical powder production as the top benefit, the preference is clear. Here’s why this stands out:

Spherical particles move more easily through machines and hoppers. This reduces clogging, enables consistent powder spreading, and improves feedstock reliability in processes like additive manufacturing.

✅ Fact: A study showed Hall flow rates improving from 103 to 35 seconds after spheroidization of titanium powders.

Uniform shapes mean fewer voids. This results in denser powder beds, stronger sintered parts, and better surface finishes in printed components.

Induction plasma eliminates satellite particles and internal voids. This leads to powders that melt uniformly and perform more reliably.

The process, known as plasma spheroidization, involves:

1. Injecting feedstock into the RF plasma torch.

2. Melting particles in-flight.

3. Allowing surface tension to form spheres.

4. Rapidly cooling and solidifying them in mid-air.

This contactless method results in smooth, dense, spherical particles free from contamination.

Induction plasma systems reach extreme temperatures, making them ideal for refractory materials like:

• Tungsten (3422 °C)

• Molybdenum (2623 °C)

• Zirconia (>2700 °C)

These materials are difficult to melt using traditional furnaces or atomization methods. Induction plasma melts them cleanly and efficiently, opening doors for aerospace and defense applications.

Since there are no electrodes or crucibles in the process, no contaminants are introduced.

This ensures:

• Ultra-pure powders (>99.9% purity possible)

• Low oxygen, nitrogen, and carbon content

• Improved mechanical properties for end-use components

This is especially vital in sectors like biomedical implants and electronics, where trace contaminants can cause failure.

Induction plasma works with:

• Metals and alloys (e.g., Ti, Ni, Re, Ta)

• Ceramics (e.g., Al₂O₃, ZrO₂)

• Composites (e.g., WC–Co)

It can process powders, wires, and even liquid precursors, making it suitable for a wide range of applications. This flexibility supports both R&D and high-volume production.

Spherical, high-purity powders are essential for laser powder bed fusion, electron beam melting, and direct energy deposition.

• Consistent powder layers

• Stronger printed parts

• Less spatter and defect formation

As metal 3D printing expands in aerospace and medical sectors, induction plasma will play a central role in powder production.

Processes like HVOF and plasma spray rely on uniform feedstock for:

• Wear-resistant coatings

• Thermal barrier layers

• Corrosion protection

Induction plasma produces the smooth, dense, free-flowing powders these methods demand.

Materials like tungsten, rhenium, and titanium aluminides are processed via plasma for:

• Rocket nozzles

• Turbine blades

• Hypersonic components

The ability to process extreme materials in high-purity form makes ICP a strategic asset.

Induction plasma also supports:

• Capacitor-grade tantalum powders

• Spherical copper for conductive pastes

• Nanopowders for batteries and semiconductors

Its flexibility makes it ideal for the miniaturization and material innovation seen in modern electronics.

The global plasma powder market is projected to grow from $3.1 billion in 2024 to $4.8 billion by 2033, driven by:

• 3D printing expansion

• Thermal spray growth

• Advanced materials demand

Companies like Tekna and others are developing high-throughput induction plasma systems (50–200 kW range) to meet rising powder needs. Systems are being optimized for:

• Higher powder yields (1–30 kg/h)

• Controlled particle size distribution

• Energy efficiency and process automation

Expect to see more closed-loop controls, real-time monitoring, and multi-coil plasma torches in the coming years.

This poll reflects a strategic shift in powder processing. Professionals value:

• Performance-enhancing shape control

• Material flexibility

• Purity assurance

• Processing capability beyond conventional means

While the top benefit was clear, each feature of induction plasma contributes to its overall value. The takeaway? Quality matters – and induction plasma delivers it on multiple fronts.

Induction plasma powder processing is no longer niche – it’s a core enabler of advanced manufacturing. As industries evolve, the demand for perfect powders will only grow.

Your poll responses echo what the market is saying: spherical powders aren’t just better—they’re essential.