L2M NSERC - Low-cost spherical powder production for metal additive manufacturing

The cost of feedstock metal powders is known to be the highest continuous expense for metal additive manufacturing (AM), regardless of procurement route, hindering versatile adoption of the technology in various industries. Additionally, during powder-based metal AM processes, a significant fraction of the used feedstock powder ends up as waste, further increasing the AM parts' production cost. This project aims to commercialize a novel method for producing low-cost spherical powders suitable for use in AM industry using metal scraps and AM wastes. In this process, the lower cost of feedstock material and reduced cost of energy as well as the high efficiency of the process result in a drastic decrease in the production cost of the produced powder, ultimately reducing the production costs associated with metal AM. This novel metal powder production and recycling technology can play a profound role in the sustainability of AM industry and acceleration of the metal AM market growth.