Polish startup revolutionizes additive manufacturing with technology that converts waste plastic into optimized spherical powders for 3D printing.
The Warsaw-based startup Alpha Powders has developed a groundbreaking technology that transforms irregular plastic waste particles into optimized spherical powders suitable for powder bed fusion 3D printing.
“Plastic was never meant to be pulverized,” said Dominik Zdybal, CEO of Alpha Powders. “It was meant to deform, be tough, not to break apart. The clue’s in the name.”
Traditional methods of pulverizing plastic result in irregular particles with poor flow properties and high internal porosity, creating significant challenges for powder bed fusion applications where material uniformity is crucial.
Alpha Powders’ proprietary spheroidization process modifies both the shape and particle size distribution of these materials. Testing shows the transformation yields uniform powders with reduced porosity, better flowability, and improved tensile strength in printed parts.
The spherical powders also reduce harmful dust emissions during handling and printing, minimizing health risks and potential equipment damage while improving consistency in the printing process.
The company is currently collaborating with equipment manufacturer Fisch Equipment to commercialize a carbon fiber-reinforced variant based on polyamide. One notable formulation offers 3 GPa stiffness with just 0.8 g/cm³ density, creating opportunities for lightweight parts with excellent surface finish.
“This is super lightweight material with very high stiffness,” Zdybal explained. “It gives you the opportunity to print very lightweight, big parts with a nice surface finish.”
Beyond creating new materials, Alpha Powders’ technology offers a novel route to recycle and upcycle both waste plastics and spent powder from additive manufacturing processes. Their system can post-process waste powder from selective laser sintering (SLS), improving its flowability and rheology to create higher-quality input than the original feedstock.
“This is upcycling in its purest form,” said Zdybal, pointing to its most recent product partnership with Fishy Filaments, which turned recycled fishing nets and reclaimed carbon fibre into sustainable 3D printing material.
The Company owns patents in major markets such as the United States, the EU, China, Korea, and Japan. Their spherodization system is suitable for any type of thermoplastic up to 260°C, even filled and colored composites.
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While Alpha Powders has hinted at a significant upcoming project, Zdybal declined to provide details, stating only that “it’s going to be huge.”
