CT-scan, SEM, EDX, flowability, rheology, permeability and tensile test analysis of recycled Ti6Al4V powders for 3D printing

This study investigates the use of three different recycled powder sets for 3D printing biomedical components, addressing the growing need for sustainable manufacturing solutions. Despite the widespread use of virgin powder in additive manufacturing, there is limited research on the performance of reconditioned powders. This study fills that gap by analyzing the performance of virgin powder, reconditioned powder, a mixed powder containing 50% fresh and 50% 7-times recycled powder, and a 7-times recycled powder (C7-only). The powders were systematically sampled, sieved, and used to print test samples such as cubes and tensile bars. The chemical composition, powder size distribution, and flowability of the powders were examined and correlated with mechanical tensile tests and porosity levels in the printed parts. Results indicate that reconditioned powder exhibits superior flowability compared to the mixed or C7-only powders. Notably, the tensile strength and strain of parts made from C7-only and mixed powders surpassed those made from virgin powder, despite a slightly higher porosity in the recycled powder samples. This study highlights the potential advantages of using reconditioned powder in the additive manufacturing of biomedical components, offering a less costly and environmentally friendly alternative for producing sensitive medical parts.