Recycled Stainless Steel as a Sustainable Feedstock for Direct Metal Laser Sintering: Challenges and Opportunities

Direct metal laser sintering (DMLS) is an advanced powder bed fusion (PBF) technology widely utilized in the medical device and aerospace sectors for the production of intricate and high-value components. The powdered metal materials used in the DMLS process can be expensive, and it is uncommon for a single build to exhaust an entire batch of powder. As a result, the un-melted powder characterized by differences in particle size and morphology compared to fresh virgin powder is recommended to be recycled for use in subsequent builds. This comprehensive review delves into the essential role that powder quality plays in the realm of DMLS with a particular focus on effective and sustainable powder recycling strategies. In this study, the effects of recycling stainless steel powder, specifically used in the DMLS process, are rigorously investigated in relation to the quality of the finished components. This paper monitors critical powder material characteristics, including particle size, particle morphology, and the overall bulk chemical composition throughout the recycling workflow. Furthermore, this review brings to light significant challenges associated with the recycling of stainless steel powders, such as the need to maintain consistency in particle size and shape, manage contamination risks, and mitigate the degradation effects that can arise from repeated usage, including wear, fragmentation, and oxidation of the particles. In addition, this paper explores a variety of recycling techniques aimed at rejuvenating powder quality. These techniques, including sieving, blending, and plasma spheroidization, are emphasized for their vital role in restoring the integrity of recycled powders and facilitating their reuse in innovative and efficient manufacturing processes.