By Rob Higby, Continuum Powders Chief Executive Officer

“Waste not, want not” resonates ever truer these days, as we become more aware of the effects of industrial byproducts on our shared environments.

While recycling of lightweight consumer-goods containers has achieved measurable success, recycling of metal waste from industrial manufacturing falls short in many ways. “Going green” is a goal that many industries give lip service. Yet, putting up a few solar panels on a domestic factory roof while buying metal powders of questionable quality, dug out of mountains and shipped across the globe, is not so green.

Fortunately, there are now better—and more profitable—ways for metal manufacturers to achieve a clearer sustainability conscience, one based in reality. Particularly in the case of metal powders used for industrial additive manufacturing (AM) and for injection molding processes, advanced plasma-atomization technology is proving its worth. Whether the used base material is Inconel, a nickel superalloy, stainless steel, titanium or just a solid, worn-out steel part, it can now be turned back into ASTM-spec powder for reuse.

This can be done at a local professional facility or even onsite with a leased or purchased one-step system, creating enticing opportunities to shorten supply chains, avoid shipping costs and freight duties, increase efficiencies at home and reduce feedstock costs. Of course, results like this lead to even bigger-picture effects such as reduced resource and energy consumption, decreased pollution and less reliance on mining and its deleterious effects on natural landscapes and water consumption.

The benefits of metal recycling are becoming increasingly evident: According to Waste Advantage Magazine, up to 80-90% of laser-powder-bed process powder may not fuse into parts, thus can be reused. However, with each reuse, the powder itself degrades in quality, leading to mandatory disposal after several cycles, depending on standards. An aerospace example shows a company saved $200,000 by avoiding incineration and reselling recycled metal-AM powders. In an alternate-use case with solid scrap-metal parts, the magazine notes that working with recycled materials can reduce costs by30-50%, and companies may avoid disposal fees of $100-$150 per ton.

Manufacturers can now reduce their greenhouse-gas footprint and lower raw material costs at the same time. What’s more, due to recent improvements in metal-powder processing technology, the powder-recycling route is not only a good economic and green decision, it’s an excellent quality decision as well.

Manufacturers are aware of the higher quality of powders produced by the more advanced atomization systems and are putting them to the test. A large aerospace OEM is in the second phase of a two-part project to recycle used or fatigued jet engine blades manufactured in a specialty superalloy. The company uses advanced plasma technology to atomize the scrap back into the highest-quality powder required for flight-certified parts. The project demonstrates the use of binder-jet 3D printing for AM on a production scale.

For expensive alloys, the supply chain is another area in which metal-powder recycling can be beneficial. Maintaining a reliable supply of essential materials can be an ongoing headache for specialty manufacturers who work with titanium, Inconel and other expensive alloys that can be a challenge to obtain in quantity. Turning existing stock into fresh powder, or purchasing it back at a reduced rate from companies that recycle it, can provide valuable assurance of stock continuity.

This is the spark of a circular metal economy. Metal-powder recycling will provide benefits in individual facilities’ bottom lines; and global sustainability efforts worldwide will provide tax incentives and carbon credits, creating even greater financial incentives to participate in tighter, closed-loop manufacturing that supports more regional and domestic resources.

This is the future of how metal powder is going to be purchased: in recycled form wherever possible; by Fortune 500 companies with serious powder needs; as well as AM machine OEMs and service bureaus. It’s leaner and cheaper, higher quality and better for the environment. We should all move in this direction.

Originally published on advancedmanufacturing.org/manufacturing-engineering - Oct 10, 2024