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Volume 14
Issue 8
10.3390/met14080886
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Review

The Challenges and Advances in Recycling/Re-Using Powder for Metal 3D Printing: A Comprehensive Review

by
Alex Lanzutti
1,* and
Elia Marin
1,2,3,4,*
1
Department Polytechnic of Engineering and Architecture, University of Udine, 33100 Udine, Italy
2
Biomaterials Engineering Laboratory, Kyoto Institute of Technology, Sakyo-ku, Matsugasaki, Kyoto 606-8585, Japan
3
Materials Innovation Laboratory, Kyoto Institute of Technology, Sakyo-ku, Matsugasaki, Kyoto 606-8585, Japan
4
Biomedical Research Center, Kyoto Institute of Technology, Sakyo-ku, Matsugasaki, Kyoto 606-8585, Japan
*
Authors to whom correspondence should be addressed.
Metals 2024, 14(8), 886; https://doi.org/10.3390/met14080886
Submission received: 5 July 2024 / Revised: 31 July 2024 / Accepted: 1 August 2024 / Published: 2 August 2024
(This article belongs to the Special Issue Advances in 3D Printing Technologies of Metals—2nd Edition)
Versions Notes

Abstract

This review explores the critical role of powder quality in metal 3D printing and the importance of effective powder recycling strategies. It covers various metal 3D printing technologies, in particular Selective Laser Melting, Electron Beam Melting, Direct Energy Deposition, and Binder Jetting, and analyzes the impact of powder characteristics on the final part properties. This review highlights key challenges associated with powder recycling, including maintaining consistent particle size and shape, managing contamination, and mitigating degradation effects from repeated use, such as wear, fragmentation, and oxidation. Furthermore, it explores various recycling techniques, such as sieving, blending, plasma spheroidization, and powder conditioning, emphasizing their role in restoring powder quality and enabling reuse.
Keywords: metal 3D printing; powder recycling; additive manufacturing; sustainability; powder degradation; L-PBF; EB-PBF; binder jetting; DED metal 3D printing; powder recycling; additive manufacturing; sustainability; powder degradation; L-PBF; EB-PBF; binder jetting; DED

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MDPI and ACS Style

Lanzutti, A.; Marin, E. The Challenges and Advances in Recycling/Re-Using Powder for Metal 3D Printing: A Comprehensive Review. Metals 2024, 14, 886. https://doi.org/10.3390/met14080886

AMA Style

Lanzutti A, Marin E. The Challenges and Advances in Recycling/Re-Using Powder for Metal 3D Printing: A Comprehensive Review. Metals. 2024; 14(8):886. https://doi.org/10.3390/met14080886

Chicago/Turabian Style

Lanzutti, Alex, and Elia Marin. 2024. "The Challenges and Advances in Recycling/Re-Using Powder for Metal 3D Printing: A Comprehensive Review" Metals 14, no. 8: 886. https://doi.org/10.3390/met14080886

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