Achieving Micron-Level Spheroidization of Non-Metallic and Metallic Powders and the Production of Nanopowders: Xi’an Sailong Unveils a Commercial Microwave Plasma Powder Manufacturing System

The commercialization of microwave plasma technology is now underway.  

According to Panda3dp.com, on February 28, 2025, Xi’an Sailong officially introduced its self-developed commercial microwave plasma powder manufacturing system at a product launch event. The registered trademark of this innovation is **Sailong Microwave™**. This state-of-the-art system integrates two core functional modules—spheroidization and nanopowder synthesis—enabling the development and production of micron-sized metallic and non-metallic spherical powders, as well as nanometer-scale powders.  

△Sailong Microwave™ Plasma Powder Manufacturing System

Microwave plasma powder synthesis is a cutting-edge technology that harnesses microwave energy to ionize gas, forming a highly reactive and high-temperature plasma environment. This facilitates the reaction or decomposition of raw materials, ultimately synthesizing micro- and nanoscale powders. The technology boasts several advantages in powder manufacturing, including high purity, precise particle size control, energy efficiency, environmental sustainability, and broad material adaptability.  

Xi’an Sailong has deeply integrated the principles of flexible manufacturing, low-carbon emission reduction, and material recycling into its technology. The company has independently developed 15kW and 25kW microwave plasma generators, equipped with an advanced powder collection and classification system, cooling system, feeding system, high-precision temperature control, and a sophisticated gas regulation system. These innovations have overcome key challenges in high-power microwave heating and precise control of multi-gas flow pressures, enabling the production of spherical powders from various grades of metallic and non-metallic materials. The system offers modular configurations for spheroidization and nanopowder production, allowing users to customize their manufacturing processes. It also enables precise control over particle size distribution, sphericity, and chemical composition, catering to the specialized requirements of industries such as additive manufacturing, energy storage, semiconductors, biomedical applications, and aerospace.  

The spheroidization module within the integrated system has successfully produced spherical powders of titanium alloys, iron-based alloys, refractory metals and their alloys, high-temperature alloys, and advanced ceramics within a particle size range of 5 to 500μm. Meanwhile, the nanopowder module has achieved the production of 10 to 500nm spherical nanopowders, including Si, Cu, Ni, carbides, nitrides, and oxides.  

△Sailong Microwave™ Plasma Powder Manufacturing Process

△Transmission Electron Microscopy (TEM) Image of Nano-Silicon Powder

△Scanning Electron Microscopy (SEM) Image of Spheroidized Refractory Metal Powder

As one of China's pioneering enterprises in the commercialization of Plasma Rotating Electrode Process (PREP) powder manufacturing technology and industrial applications, **Xi’an Sailong has leveraged its extensive expertise and technological breakthroughs in PREP powder synthesis. The company has now successfully developed Sailong Microwave Plasma Powder Manufacturing Technology and Equipment. Currently, it is collaborating with research institutions on the production techniques for micron- and nanometer-scale metallic and non-metallic spherical powders.  

In the field of microwave plasma technology and equipment, Xi’an Sailong has secured four authorized invention patents and registered 21 trademarks.  

The 2025 TCT ASIA exhibition will be held from March 17 to 19 at the National Exhibition and Convention Center (Shanghai). Xi’an Sailong will showcase its Microwave Plasma Powder Manufacturing Solutions at Booth 7K55, Hall 7.1. We warmly invite you to visit and engage in discussions.