On October 10, 2026, the journal Powder Technology published a new hybrid plasma-gas atomization method for metal powder production. The system is induction-free and crucible-free, using a custom single direct current plasma torch to directly melt metal wire for primary breakup, and is directly connected to a closely coupled gas nozzle for secondary atomization (about 1.0 MPa), unifying plasma atomization (PA) and gas atomization (GA) mechanisms in a single system. Using commercially available AISI 308L stainless steel wire as the baseline material, combined with computational fluid dynamics (CFD) simulations and experimental validation: after increasing the atomization pressure to 3.0 MPa, the median particle size (d50) decreased by 60.4%; the yield of 10–45 μm fine powder suitable for additive manufacturing reached 73.22%; higher pressure suppressed surface wrinkling, and the powder was mainly spherical. During operation, the system formed a stable dual stagnation-point recirculation zone, directly driving catastrophic secondary breakup of droplets. This architecture eliminates the bulky and contamination-prone induction melting infrastructure of conventional gas atomizers, making it particularly suitable for reactive metals and high-purity powder production, while offering a simpler structure and lower operating costs, providing a new route for lightweight powder production equipment and improved fine powder yield. Value for powder buyers: ① A fine powder yield exceeding 70% means there is still significant room for cost reduction in AM powder manufacturing, which is favorable for powder price reductions in the medium to long term; ② The crucible-free route offers process advantages for high-purity powder production of reactive metals such as titanium, and its industrialization pilot progress should be monitored; ③ The technical routes of existing plasma atomization suppliers can be included in procurement evaluations for comparison.