Reuse powder impacts in additive manufacturing for aeronautical parts

Reuse powder impacts in additive manufacturing for aeronautical parts | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Reuse powder impacts in additive manufacturing for aeronautical parts Bruna Torres Ferreira, João Monteiro, Anderson Borille, Marco Leite, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6836073/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 22 Oct, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract The reuse of powder in laser powder bed fusion offers a promising approach to optimizing material usage, reducing costs, and improving sustainability. However, its application in the aeronautical sector presents significant challenges due to strict certification requirements, process reliability concerns, and the need to maintain mechanical integrity over multiple reuse cycles. This study conducts a comprehensive and global analysis of powder reuse, considering its mechanical, economic, and environmental impacts. The methodology includes powder characterization, mechanical testing, cost modelling, and environmental life-cycle assessment, providing a holistic understanding of powder degradation and its implications. Results confirm that successive reuse cycles lead to minor changes in powder morphology and an increase in oxygen content, yet mechanical properties remain within acceptable limits, with a slight improvement in tensile strength. Economically, powder reuse significantly reduces costs, with a 33% decrease observed after a single reuse cycle and further reductions in subsequent cycles. Environmentally, the life-cycle assessment highlights substantial benefits, including a dramatic reduction in material waste, energy consumption, and carbon footprint, reinforcing the sustainability advantages of controlled powder reuse. These findings validate the feasibility of powder reuse in industrial-scale additive manufacturing. The study highlights the importance of implementing standardized reuse protocols to ensure consistency in mechanical properties, minimize variations in powder characteristics, and maintain process stability over multiple reuse cycles. Additionally, it underscores the need for further research into long-term powder recycling strategies, including controlled rejuvenation methods, advanced monitoring techniques, and predictive models for powder degradation. By optimizing reuse practices, industries can maximize cost savings, enhance material sustainability, and significantly reduce the environmental impact of additive manufacturing processes, reinforcing the viability of AM as a competitive and responsible manufacturing approach. powder reuse additive manufacturing life cycle assessment mechanical properties based-cost model sustainability Full Text Cite Share Download PDF Status: Published Journal Publication published 22 Oct, 2025 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 28 Jul, 2025 Reviewers agreed at journal 15 Jun, 2025 Reviewers invited by journal 15 Jun, 2025 Editor assigned by journal 12 Jun, 2025 First submitted to journal 10 Jun, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6836073","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":471464749,"identity":"ea2ef2b4-e823-4eab-a4a5-6678e365f0cf","order_by":0,"name":"Bruna Torres 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