6K’s UniMelt Technology: Revolutionizing Additive Manufacturing with Sustainable, High-Performance Metal Powders

The U.S. company 6K stands at the forefront of material innovation, dedicated to developing premium materials crucial for advancing burgeoning industries such as additive manufacturing, renewable energy, and more. Within the realm of 3D printing, 6K has acutely recognized the escalating demand for high-quality metals. These advanced materials are essential for enabling robust production in critical sectors like aerospace, medical, and automotive, where performance and reliability are paramount. To effectively address this growing need, 6K has pioneered a groundbreaking technology known as UniMelt. This innovative system excels at creating alloy powders that are truly spherical, virtually free of porosity and undesirable satellites, and exhibit superior flowability. These characteristics translate directly into high-performance powders that significantly enhance the capabilities of additive manufacturing processes. The UniMelt system achieves these unparalleled qualities through sophisticated spheroidization and densification processes, ensuring the production of premium-grade materials. To delve deeper into these advanced processes and understand the specific types of materials 6K is developing, we had the distinct opportunity to speak with Dr. Aaron Bent, who has served as the CEO of 6K since 2014.

3DN: Can you introduce yourself and elaborate on your connection with 3D printing?

My name is Dr. Aaron Bent, and I hold the position of CEO at 6K. I joined the company as CEO in 2014, marking me as employee number three. Today, our team has grown significantly to just under 100 dedicated employees. Over the past 25 years, I’ve had the privilege of founding or leading various technology startups across a diverse array of markets, including telecommunications, defense & aerospace, automotive, and solar energy, among others. A consistent theme throughout my career has been the understanding that advanced materials serve as the fundamental enabler for entirely new classes of products. I am constantly seeking out companies that possess a foundational ability to fundamentally alter existing methodologies, with the ultimate goal of generating a profound and lasting impact on markets and product development. 6K embodies such a company, and I can confidently say that it holds the most significant potential for impact of any organization I have been involved with throughout my professional journey. Our work in advanced materials, particularly for additive manufacturing, directly contributes to shaping the future of industrial production.

3DN: What was the genesis of 6K, and how did the idea for its development come about?

6K, originally incorporated as Amastan Technologies, began its journey as a pioneering research project at MIT. This initial phase focused on exploring the potential of microwave plasma as a novel method for synthesizing materials across a broad spectrum of markets. The research later transitioned to the University of Connecticut, where we continued to refine and expand upon the capabilities of this exciting technology. During this period, we successfully demonstrated the remarkable versatility of our platform, showcasing its ability to manufacture diverse materials, including metal powders for additive manufacturing (AM), advanced materials for energy storage applications, phosphors for next-generation LED lighting, critical semiconductor materials, defense-grade IR-transparent materials, and many other specialized composites. This wide-ranging success quickly propelled us to initiate a concentrated effort to focus and commercialize the technology. We embarked on a strategic path to meticulously match our unique capabilities with specific materials and high-value applications, ultimately leading to the formalization of our commercial strategy.

The microwave plasma technology was successfully commercialized into a formal product, which we proudly named UniMelt®. This system is a sophisticated manufacturing production platform specifically designed to create the final material used in metal powder production today. Over the course of the last five years, we have strategically honed our focus on two key markets: additive manufacturing and energy storage. This sharpened focus stems from the distinct advantages UniMelt offers to these sectors, particularly concerning sustainability, unparalleled material quality, and, in the case of additive manufacturing, the ability to produce not only common and widely used materials like Inconel 718 and Ti-6Al-4V but also entirely custom materials that were previously unavailable for AM applications. This capability opens up new frontiers for designers and engineers, allowing for the creation of components with tailored properties never before achievable.

3DN: What is the significance behind the name 6K?

Regarding our name, we recently underwent a rebranding initiative, transitioning the company name from Amastan Technologies to 6K. This new identity directly reflects the core of our UniMelt process, both in name and visually through our distinctive logo. The “6K” in our name precisely represents 6000 degrees Kelvin, a temperature that profoundly distinguishes 6K’s technology from all others in the industry. It is the exact operating temperature of our UniMelt system—specifically 5778K, to be precise. This incredibly high temperature is sustained by the world’s only microwave production-scale plasma, making our process truly unique. Interestingly, 6000 Kelvin is also approximately the temperature of the surface of the sun, a powerful metaphor for the intense energy and transformative potential embedded in our technology. This name change was a deliberate step to better communicate the revolutionary nature of our plasma technology and its ability to process materials at extreme temperatures, unlocking unprecedented possibilities for advanced material production.

3DN: Could you elaborate further on your UniMelt system and its unique capabilities?

At the very core of the UniMelt® system lies an atmospheric pressure microwave plasma generation unit. This innovative unit creates a large, highly uniform production zone with an incredibly consistent temperature distribution, a feat unmatched by conventional arc-electrode or inductively-coupled plasmas. It is absolutely crucial to emphasize that UniMelt is fundamentally different from traditional Gas Atomization (GA) or Plasma Atomization (PA) processes. UniMelt stands alone as the world’s *only* microwave-based plasma system for metal powder production. Operating at an astonishing 6000 degrees Kelvin, the UniMelt system possesses the unparalleled capability to process a vast array of materials, including ceramics, pure metals, and complex alloys. This includes not only widely used additive manufacturing metals like Inconel 718 or Ti-6Al-4V but also opens the door to creating custom alloys that have never before been available for additive manufacturing, effectively expanding the material palette for advanced design and engineering.

This expanded material capability is truly transformative. Organizations can now embark on design endeavors with an unprecedented range of materials because virtually any metal or alloy that can be machined can now be successfully transformed into feedstock for 6K’s premium powders. Unlike many traditional methods that rely on wire or ingot as feedstock, UniMelt ingeniously utilizes certified machining scrap. This paradigm shift dramatically broadens the possibilities for premium AM powder production to include any material typically processed using subtractive technologies, such as CNC machining. Furthermore, our technology offers significant sustainable advantages: we can rejuvenate used additive manufacturing powder, and even repurpose AM supports and failed builds as feedstock for the UniMelt process. This capability is critical on two distinct yet interconnected fronts. Firstly, by starting with certified chemistry in the form of scrap or used powder, we can meticulously ensure and maintain certified chemistry in our final products. Secondly, and equally importantly, we are actively driving the circular economy model, delivering the world’s first premium AM powder derived from truly sustainable and reclaimed sources, significantly reducing waste and environmental impact.

In essence, the UniMelt system consistently delivers:

• A highly uniform plasma production zone, ensuring consistent material processing.
• A continuous, zero-contamination process, vital for high-purity materials.
• Exceptional energy efficiency, with over 99% microwave-to-plasma conversion.
• The flexibility to operate in inert, reducing, and oxidizing atmospheres, accommodating diverse material requirements.

3DN: What specific types of materials are you capable of producing for the additive manufacturing market?

This is an excellent question and truly highlights a key differentiator for 6K in the additive manufacturing landscape. As previously mentioned, the UniMelt system innovatively utilizes certified machined scrap, used powders, and other reclaimed materials as feedstock. This groundbreaking approach unlocks a vast world of new possibilities for AM, allowing for the production of materials that were once impractical or impossible. At Formnext, a premier industry event, we proudly showcased several key examples of our capabilities. These included widely sought-after materials such as INCONEL 718, INCONEL 625, Ti-6Al-4V, MOLYBDENUM, RHENIUM, STAINLESS STEEL 17-4, ALUMINUM AlSiMg, TANTALUM, TUNGSTEN, and 8% YTTRIA STABILIZED ZIRCONIA. These materials are crucial for various high-performance applications across aerospace, medical, and industrial sectors.

Beyond these established materials, a significant highlight from Formnext in Frankfurt last November was the demonstration of the world’s first High Entropy Alloy (HEA) produced using our technology. High Entropy Alloys represent a revolutionary class of materials, opening up limitless possibilities for designers and engineers. They enable the creation of a ‘perfect blend’ of elements, allowing for the precise tailoring of properties to meet specific application demands. For instance, HEAs can be engineered to exhibit exceptional combinations of high strength coupled with superior elongation, achieve remarkably higher strength-to-weight ratios, or maintain stable properties over an extremely wide range of temperatures. This ability to customize material performance at such a fundamental level promises to accelerate innovation across countless industries.

Our success is also underpinned by the extensive expertise of our production team, which boasts over 20 years of collective experience and profound knowledge in alloys, metals reclamation, and advanced powder production techniques. We are particularly excited about the ongoing expansion of our production plant, which involves adding 40,000 square feet of additional production space to our facility located just outside Pittsburgh, PA. Our current production plant already plays a significant role in the industry, selling over 1 million pounds of reclaimed titanium annually into premium alloying markets for aerospace, medical, and automotive industries. The facility is ISO9001 certified, with AS9100 certification expected in Q3 of this year, underscoring our commitment to the highest quality standards. The new 40,000-square-foot addition will be primarily dedicated to the production of additive manufacturing powders, significantly augmenting our already successful metals reclamation business and positioning us to meet the escalating demand for advanced AM materials.

3DN: Who are your primary target markets, and what kinds of applications are they developing with your materials?

Our initial material slated for full-scale production is Inconel 718. Consequently, our primary target markets for this material are those that extensively utilize its unique properties. These include the demanding aerospace sector, where heat and corrosion resistance are critical for engine components and structural parts; the oil and gas industry, requiring robust materials for extreme environments; land-based turbines for power generation; and various other industrial markets that depend on Inconel 718’s exceptional characteristics, particularly its resilience to high temperatures and corrosive conditions. Later this year, we plan to introduce Ti-6Al-4V, a highly versatile material that will cater to the aforementioned markets while also significantly expanding our reach into the medical device and implant space, where biocompatibility and strength are paramount for applications like prosthetics and surgical instruments. As previously discussed, our work on High Entropy Alloys (HEAs) is progressing rapidly, and we are actively engaging in partnership discussions with leading organizations within the aerospace/defense markets and the oil and gas sector. Given their tremendous application possibilities and the ability to tailor their elemental composition for specific advantages, HEAs hold the potential to address the needs of many other markets, ushering in a new era of material science and component design.

It is also crucial to highlight another significant advantage of the UniMelt system: its capability to achieve a tunable Particle Size Distribution (PSD) with a remarkable 100% yield. This precision allows 6K to efficiently produce metal powders specifically optimized for a wide array of additive manufacturing technologies. This includes powder bed fusion processes like Selective Laser Sintering (SLS) and Selective Laser Melting (SLM), Electron Beam Melting (EBM), and Binder Jetting, as well as direct energy deposition techniques and cold spray. Furthermore, our powders are perfectly suited for traditional powder metallurgy (PM) processes such as Metal Injection Molding (MIM) and Hot Isostatic Pressing (HIP). This versatility in tailoring PSD ensures that our customers receive the exact material specifications required for their particular application and chosen manufacturing method, maximizing efficiency and performance across the board.

3DN: What are the main advantages of your plasma technology compared to other methods?

The UniMelt® system represents a highly robust and sophisticated production platform, engineered to deliver the absolute highest quality premium powder for additive manufacturing. Our powders consistently achieve superior characteristics, including exceptional sphericity, near-zero porosity, and the fewest satellites of any powder manufacturing technology currently available. These qualities are critical for optimal flowability, uniform melting, and ultimately, the production of defect-free, high-performance parts. What truly sets UniMelt apart is its pioneering approach to sustainability: it exclusively leverages sustainable sources as feedstock. Whether it’s certified millings from CNC operations, grindings, previously used additive manufacturing powder, or even the support material generated during builds, UniMelt transforms what was once waste into valuable raw material. This means there is virtually no excess waste or cut-size material that ends up in landfills or sits idly in warehouses, incurring write-offs. Furthermore, UniMelt offers unparalleled flexibility in tailoring the Particle Size Distribution (PSD) precisely to the requirements of any particular additive process. This capability empowers organizations not only to meet existing specifications but also to actively alter PSDs to advance material properties or fine-tune them for even higher performance outcomes, pushing the boundaries of what’s possible in additive manufacturing.

UniMelt is unequivocally the world’s most capable plasma production system, meticulously engineered for:

• A highly sustainable process, minimizing waste and maximizing resource utilization.
• High volume production, capable of producing up to 100 tons of powder per year.
• A continuous feed process, unrestricted by the limitations of wire or ingot feedstock, ensuring uninterrupted operation.
• Exceptional versatility, capable of processing a wide range of materials including ceramics, metals, alloys, and even thermoplastics.
• Maintaining a highly uniform plasma zone, crucial for consistent material quality and properties.
• High uptime systems, driven by precise recipes and enabled by remote operation capabilities, ensuring efficiency and reliability.
• Producing a broad spectrum of particle sizes, from nano-scale through to hundreds of microns, catering to diverse application needs.

3DN: Do you have any final message for our readers?

As an organization, we are incredibly excited about the profound impact we are making on the additive manufacturing market and our ability to help customers significantly advance their production capabilities with 6K’s premium powders. Our overarching goal is to enable a superior business case for AM designers and engineers through three core pillars:

**Infinite Materials Choices:** Our mission is to empower customers to build with an almost infinite array of material options, liberating them from the limitations of today’s restrictive material selections. Our goal is to actively assist them in developing innovative new products that not only meet but far exceed market expectations, providing them with an expansive choice of high-performance material options sourced from 6K. This freedom to innovate with materials will unlock unprecedented design possibilities.

**Highest Performance Parts:** We are committed to ensuring that our customers consistently build the highest performance parts imaginable. This commitment means leveraging the inherent strengths of the UniMelt technology to produce powder with zero porosity, exceptional sphericity, virtually no satellites, and superior flowability—all while rigorously meeting or surpassing stringent ASTM specifications. These characteristics translate directly into stronger, more reliable, and more efficient printed components.

**Building for a Circular Economy:** Lastly, and with great emphasis, we aim to encourage our customers to adopt sustainable manufacturing practices and actively contribute to a thriving circular economy. This initiative extends beyond simply utilizing 6K powder; it involves forging collaborative partnerships with 6K to repurpose their certified machine scrap, used additive powder, and other potential sources of feedstock. Through this partnership, these materials can be effectively rejuvenated and transformed back into premium powder, drastically reducing waste and promoting environmental stewardship within the additive manufacturing ecosystem.

What are your thoughts on 6K’s innovative system for developing advanced materials specifically for additive manufacturing? We invite you to share your insights in a comment below or join the conversation on our Facebook and Twitter pages! Don’t forget to sign up for our free weekly Newsletter to receive all the latest news in 3D printing directly in your inbox!