Rerouting material streams in the additive manufacturing values chain
The project addresses the sustainability challenge in additive manufacturing by recycling degraded 316L stainless steel powder and scrap from the printing process. Using innovative re-melting and gas atomization methods, new powder with low oxygen content and good processability was produced. This circular approach reduces material waste and reliance on virgin resources, supporting both environmental and economic goals in metal AM.
Project description
This project focuses on enhancing the sustainability of metal additive manufacturing (AM), specifically targeting 316L stainless steel used in powder bed fusion – laser beam (PBF-LB) processes. In AM, a large portion of the powder becomes unusable after multiple print cycles due to oxidation and spatter, while support structures and failed prints add to material waste.
To address this, the initiative develops a recycling process where scrap and degraded powders are re-melted and atomized into new powders using a vacuum induction furnace and high-pressure gas atomization with close-coupled nozzles. The resulting powder is then classified, tested for oxygen content, morphology, and flowability, and validated for reuse in PBF-LB.
The innovation lies in combining industrial-scale reprocessing with advanced surface analysis to ensure powder quality comparable to virgin materials. Tests show that re-atomized powder has excellent printability and lower surface oxidation.
The project, conducted by Swerim AB, Chalmers University of Technology, and Alfa Laval AB under the Vinnova-funded RECIRCLE and CAM2 initiatives, demonstrates the feasibility of circular material flows in AM. This promotes reduced waste, resource efficiency, and cost savings—contributing to a more sustainable and economically viable manufacturing future.
Project goals
The main goal of this project is to establish a sustainable method for recycling 316L stainless steel powders and scrap from additive manufacturing (AM) processes. It aims to turn waste—such as unused powder, support structures, and failed builds—into high-quality feedstock suitable for reuse in powder bed fusion – laser beam (PBF-LB).
A key target is to reduce the oxygen content and oxide layer thickness on the recycled powder through re-melting and gas atomization. Ensuring good flowability and layer density is also critical for print performance. The project applies advanced characterization tools like SEM and XPS to confirm the chemical and morphological integrity of the re-atomized powder.
Another important goal is to support the shift toward a circular economy in AM, enabling manufacturers to reduce reliance on virgin materials and cut costs. The process is tested on an industrial scale using a state-of-the-art VIGA atomizer, simulating realistic production conditions.
By validating the technical and economic viability of using recycled scrap in AM, the project helps industries adopt more resource-efficient and sustainable practices. It also provides valuable guidelines for powder reuse, atomization optimization, and quality assurance in recycled AM feedstocks—paving the way for greener, cost-effective metal manufacturing.