High material costs, unstable processes, or limited material properties?
The root cause often lies at the particle level.
We coat each individual powder particle precisely (core–shell structures), thereby modifying interfaces that determine process and material behavior.
- Precise control of diffusion, reactivity, and alloying in powder metallurgy
- Improved laser absorption and more stable processes in additive manufacturing
- Reduced use of precious metals through functional surfaces, e.g., catalysis
Typical Process: Technical Coordination → Concept Development → Sample Production
Why standard powders are often the limiting factor?
In many applications, processes and materials are intensively optimized – through system parameters, process control, or alloys.
Nevertheless, key challenges remain:
- Significant effort required in materials development
- Uneven distribution of alloy powders
- Limited material properties
- Unstable processes
In many cases, the behavior of powders is determined by the surface of each individual particle – not by its volume.
Specific particle coating instead of material modification
Coating individual powder particles results in core-shell particle:
- Core: existing powder
- Shell: application of a defined functional surface layer
Brief Technical Assessment of Your Application
By selectively coating individual particles, material and process properties can be precisely tailored.
From Surface Properties to Process Behavior
The surface determines how a particle reacts during the process. This reaction can be controlled through selective coating.
-
Why the particle surface is often more important than the material itself
Read more: Why the particle surface is often more important than the material itselfWhen it comes to powders, attention is often focused on their chemical composition or alloy. In many industrial applications, however,…
-
Impact on Processes, Materials, and Development
Read more: Impact on Processes, Materials, and DevelopmentThe development of new materials and processes traditionally takes place through the adjustment of alloys, equipment parameters, or process workflows.…
Typical Applications of Functionalized Powder Particles
Particle coating is always relevant whenever surface properties determine the process or material behavior.
The crucial factor is not the material alone, but how the particle surface behaves during the process.
Typical applications can be found in the following areas:
Additive Manufacturing (LPBF, DED, SLM, SLS, Ceramic 3D Printing)
Problems
- Unstable melt baths
- Low or inconsistent energy absorption
- Limited processability of certain materials (e.g., Cu, Al)
- Insufficient powder flowability
- Inconsistent mixing of alloying elements
Physical cause
The interaction between laser and material is determined by the particle surface:
- Reflection vs. Absorption
- Oxide Layers and Surface Energy
- Agglomerations
Solution (nano2b approach)
Customized particle surface modification through functional coating:
- Altered optical properties
- Controlled interfaces
- Targeted distribution of alloying elements
Result
- More stable processes and expanded process windows
- Improved energy input, resulting in shorter pressing times
- Powders that were previously non-flowable can now be used
- Homogeneous alloys
Catalysis and Functional Surfaces
Problems
- High demand for precious metals
- Inefficient use of active surface area
Physical cause
Catalytic activity occurs exclusively at the surface:
- Reactions take place at only a few active sites
- Volume material is often not utilized
Solution (nano2b approach)
Deposition of active materials onto low-cost carrier particles:
- Deliberatly functionalizing the surface
- Controlled distribution of active sites
Result
- More efficient use of expensive materials
- Potentially lower material costs
Abrasive Materials and Composite Systems
Problems
- Abrasive grains or functional additives do not adhere well to binder or matrix systems.
- Wetting between the abrasive particles and the matrix is insufficient.
- Fine additives are difficult to distribute homogeneously.
- Agglomerates and local variations in concentration form during powder mixing.
Physical cause
The interface between the abrasive particles and the matrix plays a key role in determining the bond strength within the composite. If the surface properties of the two materials are incompatible:
- the surface is poorly wetted
- weak interfaces form
- forces cannot be transmitted efficiently
Solution (nano2b approach)
The surface of the abrasive particles is specifically treated with a functional coating. The shell is selected so that it:
- has a high affinity for the abrasive grain
- while also enabling good interaction with the matrix
Result
- Improved adhesion in the composite
- Evenly distributed additives
- Reduced agglomeration
- Reproducible grinding properties
Pulvermetallurgie und Sinterprozesse
Problems
- Diffusion that is difficult to control
- Variable microstructures
- Limited ability to adjust properties (e.g., porosity, hardness, conductivity, …)
- Non-repeatable mixing of powders during alloying
Physical cause
Sintering and diffusion processes begin at the particle surface:
- Interfaces determine mass transfer
- Local chemical conditions dominate
- Agglomerations
Solution (nano2b approach)
Deliberate control of interfaces through particle coating:
- Controlled diffusion (inhibited or enhanced)
- Controlled contact areas
- Controlled amount and distribution of the alloy material
Result
- More reproducible microstructure
- Targeted material properties
- Homogeneous alloy
Alloy Development
Problems
- Alloying elements are difficult to distribute homogeneously
- Fine additives agglomerate during powder mixing
- New alloys require significant development and qualification efforts
Physical cause
Fine alloy additives have a high specific surface area and are therefore prone to agglomeration and segregation. This results in:
- Inhomogeneous microstructure
- Uneven distribution of additives
- Local variations in concentration
Solution (nano2b approach)
Instead of developing new powders, existing powders undergo deliberate surface modification:
- Alloying additives are applied directly to the carrier particles
- Uniform distribution on each individual particle
- Existing powders can continue to be used
Result
- uniform distribution of alloying elements
- faster and more cost-effective material development
- reduced mixing effort
- reproducible material properties
- more efficient use of alloying additives
Other Applications and Areas
- Powder Recycling (Surface Reactivation)
- Functional Additives in Composite Materials
- Adjustment of Flow Behavior and Interactions
- Medical Technology
- Metallurgy
- Chemical Industry
- Aerospace
- Scientific
- Metal Injection Molding
- Ceramics Industry
- Coating Processes (Thermal Spraying, Cold Gas Spraying)
Initial Technical Assessment of Your Application
For specific requirements and ongoing projects
How a Collaboration Works
The development of functionalized powders takes place in several clearly defined steps – from analyzing the application to providing coated particles.
1. Understanding the Application
Together, we’ll clarify::
- Current Challenges
- Process and Application Area
- Relevant Material and Target Parameters
2. Coating Concept
Based on this, we will work together to develop a suitable plan:
- Derivation of the Desired Interface Properties
- Definition of the Layer Architecture
- Selection of Core Material and Coating (Shell)
3. Production of Coated Particles
Implementation is carried out using a defined coating process:
- Controlled deposition of functional layers
- Reproducible fabrication of core-shell structures
4. Evaluation by the Customer
Validation takes place in the respective application system:
- Tests at the customer’s site under real-world process conditions
- Feedback on behavior and performance
- Adjustment and further development of the coating
5. Production
We remain your manufacturing partner
- Prototypes
- Small-batch to large-scale production
We work with you to develop a material solution tailored to your specific application.
A typical way to start is with a brief technical discussion in which current ideas and problems are discussed and solutions are identified.
Initial Technical Assessment of Your Application
For specific requirements and ongoing projects
Technological expertise from research and practical application
We combine extensive experience in thin-film technology and surface physics with a physical understanding of interfaces in powder systems.
The focus is on understanding and the controlled design of interfaces.
We are a young, dynamic and agile team with a passion for technological innovation. With over 20 years of combined experience in thin film technology and PVD coating of powders, we blend scientific expertise with industrial practice.
Jürgen Bauer
Strategy & Implementation
Co-Founder
The crucial factor is whether a solution can be implemented in the real process.
Many material-related effects occur at the surface – that is exactly where we focus.
David Böhm
Technology & Development
Co-Founder
Frequently Asked Questions (FAQ):
General Questions:
How does a collaboration begin?
A typical start is with a brief description of your application.
The next step is a technical discussion, during which we’ll assess the issue together and determine possible next steps.
Does the problem need to be fully defined?
No.
Even an initial observation or a general question is enough to start a technical discussion.
How much does a particle coating cost?
The costs depend heavily on the specific application.
The following factors are particularly important:
- the coating material
- the thickness or mass fraction of the coating (which, in turn, depends heavily on the size of the powder)
It is therefore not appropriate to provide a general statement.
How long will the project take to complete?
Materials are typically procured on a project-by-project basis through an existing network of suppliers.
Relevant are in particular:
- Procurement of the base powder (core)
- Availability of the coating material (shell)
The process begins quickly with a technical discussion.
Who tests the coated powder particles?
Generally, we develop and supply the coated particles; evaluation takes place within the customer’s specific application system.
In addition, through our collaboration with a broad network of laboratories and scientific partners—in particular the Technical University of Vienna—we have access to a wide range of measurement methods for characterizing the particles and their surface properties.
Is this a standard product or a custom solution?
This is a customized solution.
The coating is developed specifically for each application, based on the material, process, and objectives.
Why coat existing powders instead of developing new alloys?
By selectively functionalizing the particle surface, properties can be modified without completely replacing the base material. This often allows new approaches to be evaluated more quickly and cost-effectively (faster iteration in materials development) than through the development of new alloys.
Why is the adjustment made through the surface rather than through the bulk material?
In many applications, interfaces and surface properties play a key role in determining a powder’s behavior. By specifically modifying the surface, these properties can be altered without having to redesign the entire material system.
In a sense, the powder is adapted to the process with minimal changes to the alloy.
What is the difference between nano2b and powder coating?
Traditional powder coating refers to the process of coating components.
The goal of nano2b is to apply deliverte coatings to individual powder particles in order to specifically influence their behavior.
Questions about the Powder (Core):
What powder materials can be used as a core?
In general, metallic, ceramic, and hybrid powders can be used. These include, for example:
- Special Materials or Blending Systems
- Metals (e.g., Cu, Al, Fe, alloys)
- Ceramics (e.g., oxides, carbides)
Are there any restrictions on the core material?
We use a vacuum process and load the system under atmospheric conditions (an inert atmosphere is also possible for smaller quantities). Therefore:
- Stable under vacuum conditions
- No undesirable chemical reactivity with oxygen in the atmosphere
- Thermal stability
What powder geometries can be coated?
The coating is generally independent of the particle shape. Typical geometries include:
- spherical particles
- irregular or fractured particles
- dendritic powders
- flocculent structures
Does the particle shape affect the coating?
Yes.
Among other things, particle geometry determines the effective surface area and influences the uniformity of the coating (e.g. in undercuts).
What grain sizes are possible?
Typical ranges are between approximately 1 µm and 1 mm.
Can different particle size distributions be processed?
Yes.
Both narrow and broad particle size distributions are generally possible. The coating is homogeneous across all fractions.
Do powders need to be specially prepared?
That depends on the raw material.
Key factors include:
- Surface Cleanliness
- Oxide or Contamination Layers
- Moisture or Adsorbates
These can affect the interaction between the core and the shell.
Can existing powders be used as raw materials?
Yes.
Existing commercial or customer-supplied powders can be used as a starting point and enhanced with a functional surface coating. These are either sourced by us or provided by you.
Questions about the Coating (Shell):
Is the coating uniform on all particles??
Yes.
The goal is to achieve a coating on the individual particles that is as uniform and reproducible as possible.
What materials can be used as a coating (shell)?
Several classes of materials can be considered for use as coatings:
- Metals
- Alloys
- Ceramic materials
- Oxides or nitrides
- Combinations thereof
Can the coating be made of multiple materials?
Yes.
The coating can be made of:
- individual layers
- multiple layers (multilayer)
- gradients (continuous transition)
What types of layered architectures are possible?
Typical layered architectures include:
- Simple core–shell structures
- Multilayer systems (e.g., A/B/A)
- Gradient structures (e.g., from A through A/B 50/50% to B)
How thick are the coatings?
Typical coating thicknesses range from:
- sub-nanometer
- up to a maximum of about 1 µm
This depends heavily on the particle size and particle size distribution of the powder. As a general rule, the smaller the powder particles are, the larger the effective surface area to be coated.
How does the layer thickness affect the mass fractions?
Since the layers are very thin, the typical mass fractions are:
approx. 1 ppm to ~10%
At what temperatures is the coating applied?
The coating is applied at relatively low temperatures (< 250 °C).
If the temperature is to remain lower, this can be achieved by using longer coating times with a lower depositionrate.
Is a high flowabily or pourability required?
No.
Flow behavior is not a strict requirement for the coating.
The flow behavior will be influenced by the chosen coating.
An initial assessment is often possible simply by observing the movement of the particles (e.g., by swirling a transparent container filled with a small amount of powder).
Initial Technical Assessment of Your Application
For specific requirements and ongoing projects