Metal powder-based manufacturing process in low impurity gas atmosphere and system

A metal powder-based manufacturing system comprising:

• a sealed vessel defining a manufacturing chamber containing a total gas volume;
• a metal transformation/conversion unit comprising one of an additive manufacturing unit using powder particles and a metal-based powder manufacturing unit configured to atomize powder particles, wherein the powder particles have a mean diameter ranging between about 10 μm and about 125 μm, wherein the metal conversion unit is contained in the manufacturing chamber and configured to heat a metal-based feedstock;
• an inert gas source in gas communication with the manufacturing chamber to supply inert gas therein, the inert gas source being operatively connected to the manufacturing chamber through an inert gas line;
• at least one gas purifying unit in gas communication with the manufacturing chamber to purify the inert gas to obtain a purified inert gas having an oxygen partial pressure below about 100 ppb;
• and
• a recirculatory scrubbing system including a closed-loop recirculation gas line extending between a recirculatory gas inlet port and a recirculatory gas outlet port defined in the vessel and in gas communication with the manufacturing chamber;
• wherein the recirculatory scrubbing system is configured to recycle between 1 and 50% (vol.) of the total gas volume per minute;
• and
• wherein at least one of the at least one gas purifying unit is mounted to the closed-loop recirculation gas line and in gas communication therewith to purify the inert gas flowing therein to produce the purified inert gas having the oxygen partial pressure below about 100 ppb.