PyroGenesis Receives New U.S. Patent for Its Innovative NexGen™ Plasma Atomization Metal Powder Production Technology for Use in Additive Manufacturing and 3D Printing

By: PyroGenesis Canada Inc. via GlobeNewswire

December 18, 2023 at 07:30 AM EST

MONTREAL, Dec. 18, 2023 (GLOBE NEWSWIRE) -- PyroGenesis Canada Inc. (http://pyrogenesis.com) (TSX: PYR) (OTCQX: PYRGF) (FRA: 8PY), a high-tech company (the “Company” or “PyroGenesis”) that designs, develops, manufactures and commercializes advanced plasma processes and sustainable solutions which are geared to reduce greenhouse gases (GHG) and address environmental pollutants, is pleased to announce that the United States Patent and Trademark Office (“USPTO”) has issued to the Company a new U.S. Patent No. US 11839918 encompassing the Company’s NexGen™ plasma atomization powder.

This U.S. Patent, entitled, “Method and Apparatus for Producing High Purity Spherical Metallic Powders at High Production Rates From One or Two Wires”, describes the Company’s NexGen^™ plasma atomization technology for producing metal powder for use in additive manufacturing and 3D printing. In particular, the patent describes the innovative aspects of the NexGen^™ system that create the potential for higher and more efficient production rates, including a two-wire simultaneous feedstock approach where the wires themselves are electrically charged prior to reaching the plasma atomization step.

According to Mr. Pierre Carabin, PyroGenesis’ Chief Technology Officer and Chief Strategist, and the co-inventor of the technology, “The NexGen^™ process is a significant departure from conventional plasma atomization, as the improved efficiency from NexGen^™not only targets higher production rates, but also narrower particle size distribution for more uniformity and consistency, and an ability to tailor particle size distribution (“PSD”) to customer requirements.”

“For PyroGenesis, that means producing more powder in a single system and with only a single plasma torch – in accordance with our commodity security and optimization business strategy. For our customers, that means they receive the finest, most spherically-consistent, and densest powders from typical plasma atomization, but with the added benefits of buying from a North American-based source that offers higher yield and less waste of a recognized critical mineral, while also being more energy efficient – helping them to reduce their carbon footprint and meet their Scope 3 emissions targets,” continues Mr. Carabin.

Traditional plasma atomization – using either a single wire centrally fed through a plasma torch, or three plasma torches aiming at one centrally-positioned wire – has a primary disadvantage of having a relatively low production rate in comparison to water and gas atomization, due to the fact that plasma atomization is a very energetically inefficient process.

To combat this, PyroGenesis Additive’s NexGen^™ system feeds two separate spools of metal wire (such as titanium) that are first electrically charged, creating an electrical arc that melts the wire before a plasma torch atomizes the melted wire into powder particles using a supersonic plasma stream. This results in a more efficient atomization of the metal – raising production output significantly.

“Plasma atomization is considered the gold standard for the production of Additive Manufacturing powder,” said Mr. Massimo Dattilo, Vice President of PyroGenesis Additive. “PyroGenesis not only invented the process, but coined the name, which is now widely used in the industry. Because of our dedication to continuous improvement, when we decided to re-enter the market, we did so with a mandate to advance plasma atomization to the next level through a redesigned system we named “NexGen”. The confirmation of this U.S. patent for NexGen^™ is a key validation of our approach and another major box checked in our market re-entry progress.”

The Company has patents pending in Canada and in other global jurisdictions for the same NexGen^™ plasma atomization process.

“The substantially improved efficiency of NexGen^™, which has shifted the particle size distribution of our production runs, means the larger average amount of finer cut powder we can produce per run also includes fine powders in the 5μm – 20μm range suitable for use in binder jetting and metal injection molding (“MIM”). We see MIM – in addition to the fine powders we can offer for laser bed applications – as a key market ahead, as more companies especially in consumer electronics continue to move from stainless steel to titanium to achieve weight and corrosion reduction,” added Mr. Dattilo.

After several years of R&D, the Company recently announced full commercialization and full entrance into the titanium metal powders marketplace with its first by-the-tonne commercial order, and the Company’s journey to create its NexGen^™ system was the topic of a recent a cover story of major additive manufacturing industry magazine ‘Powder Metallurgy Review’.

“With a goal to produce the highest quality metal powders in the additive manufacturing industry, PyroGenesis Additive has taken a cautious, methodical approach over the past few years as we designed, then readied, our new NexGen^™ plasma atomization process,” said Mr. P. Peter Pascali, President and CEO PyroGenesis Canada Inc. “With full commercialization achieved, and now with the U.S. patent confirmed for our technology, we look forward with great optimism regarding our future, with an ever-widening range of metal powder offerings becoming available to the additive manufacturing industry.”

The Company’s development of high quality titanium metal powders is part of the Company’s three-tiered solution ecosystem that aligns with economic drivers that are key to global heavy industry. Metal powders is part of the Company’s Commodity Security & Optimization tier, where the recovery of viable metals, and the optimization of production to increase output, helps to maximize raw materials and improve the availability of critical minerals. Titanium has been identified as a critical mineral by the Canadian government and many other governments worldwide.

About PyroGenesis Canada Inc.

PyroGenesis Canada Inc., a high-tech company, is a proud leader in the design, development, manufacture and commercialization of advanced plasma processes and sustainable solutions which reduce GHG and are economically attractive alternatives to conventional “dirty” processes. PyroGenesis has created proprietary, patented and advanced plasma technologies that are being vetted and adopted by multiple multibillion dollar industry leaders in four massive markets: iron ore pelletization, aluminum, waste management, and additive manufacturing. With a team of experienced engineers, scientists and technicians working out of its Montreal office, and its 3,800 m² and 2,940 m² manufacturing facilities, PyroGenesis maintains its competitive advantage by remaining at the forefront of technology development and commercialization. The operations are ISO 9001:2015 and AS9100D certified, having been ISO certified since 1997. For more information, please visit: www.pyrogenesis.com.

Cautionary and Forward-Looking Statements

This press release contains “forward-looking information” and “forward-looking statements” (collectively, “forward-looking statements”) within the meaning of applicable securities laws. In some cases, but not necessarily in all cases, forward-looking statements can be identified by the use of forward-looking terminology such as “plans”, “targets”, “expects” or “does not expect”, “is expected”, “an opportunity exists”, “is positioned”, “estimates”, “intends”, “assumes”, “anticipates” or “does not anticipate” or “believes”, or variations of such words and phrases or state that certain actions, events or results “may”, “could”, “would”, “might”, “will” or “will be taken”, “occur” or “be achieved”. In addition, any statements that refer to expectations, projections or other characterizations of future events or circumstances contain forward-looking statements. Forward-looking statements are not historical facts, nor guarantees or assurances of future performance but instead represent management’s current beliefs, expectations, estimates and projections regarding future events and operating performance.

Forward-looking statements are necessarily based on a number of opinions, assumptions and estimates that, while considered reasonable by the Company as of the date of this release, are subject to inherent uncertainties, risks and changes in circumstances that may differ materially from those contemplated by the forward-looking statements. Important factors that could cause actual results to differ, possibly materially, from those indicated by the forward-looking statements include, but are not limited to, the risk factors identified under “Risk Factors” in the Company’s latest annual information form, and in other periodic filings that the Company has made and may make in the future with the securities commissions or similar regulatory authorities, all of which are available under the Company’s profile on SEDAR+ at www.sedarplus.ca, or at www.otcmarkets.com. These factors are not intended to represent a complete list of the factors that could affect the Company. However, such risk factors should be considered carefully. There can be no assurance that such estimates and assumptions will prove to be correct. You should not place undue reliance on forward-looking statements, which speak only as of the date of this release. The Company undertakes no obligation to publicly update or revise any forward-looking statement, except as required by applicable securities laws.

Neither the Toronto Stock Exchange, its Regulation Services Provider (as that term is defined in the policies of the Toronto Stock Exchange) nor the OTCQX Best Market accepts responsibility for the adequacy or accuracy of this press release.

For further information please contact:

Rodayna Kafal, Vice President, IR/Comms. and Strategic BD
Phone: (514) 937-0002, E-mail: ir@pyrogenesis.com

Massimo Dattilo, Vice President, PyroGenesis Additive
Phone: (438) 797-7673, E-mail: mdattilo@pyrogenesis.com

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