A powder recycling system includes a supply tank, a continuous loss-in-weight module, a pneumatic module, a transfer channel, a recycle module, and a refilling tank. The supply tank accommodates recycling powder. The continuous loss-in-weight module includes a storage tank receiving the recycling powder from the supply tank and a rotary output pipe connected to the storage tank to output the recycling powder. The continuous loss-in-weight module controls the mass flow rate of the output of the recycling powder according to the weight change of the storage tank. The pneumatic module enables the recycling powder to float and move in the transfer channel. The recycle module is connected to the transfer channel to receive the recycling powder, sieves the recycling powder, provides virgin powder, and mixes the virgin powder with the recycling powder. The refilling tank is connected to the recycle module to receive the recycling powder and the virgin powder.

A method of additively manufacturing a part is provided. The method includes flowing masticated particles through a deposition nozzle of a directed energy deposition additive manufacturing apparatus. Each particle of the masticated particles includes a surface formed by at least angular facets. The method also includes melting the masticated particles exiting the deposition nozzle with a directed energy source of the directed energy deposition additive manufacturing apparatus so as to form the part.

A method of additively manufacturing a part is provided. The method includes flowing masticated particles through a deposition nozzle of a directed energy deposition additive manufacturing apparatus. Each particle of the masticated particles includes a surface formed by at least angular facets. The method also includes melting the masticated particles exiting the deposition nozzle with a directed energy source of the directed energy deposition additive manufacturing apparatus so as to form the part.

Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, and recycled used powder. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.

Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, and recycled used powder. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.

The invention relates to a method for preparing waste powder from generative production processes, by means of which three-dimensional objects are produced in layers from a powdery base material. The aim of the invention is to provide a method for the combined mechanical and material preparation of waste powder, wherein the waste powder is brought into such a structure that subsequently, by mixing with or even without new powder or mixtures of new and waste powders, a high-quality powdery material becomes available for generative production processes. This aim is achieved in that the waste powder is subjected to a mechanical treatment by reducing the waste powder to small pieces with a grinding mill.

The invention relates to a method for preparing waste powder from generative production processes, by means of which three-dimensional objects are produced in layers from a powdery base material. The aim of the invention is to provide a method for the combined mechanical and material preparation of waste powder, wherein the waste powder is brought into such a structure that subsequently, by mixing with or even without new powder or mixtures of new and waste powders, a high-quality powdery material becomes available for generative production processes. This aim is achieved in that the waste powder is subjected to a mechanical treatment by reducing the waste powder to small pieces with a grinding mill.

An expeditionary additive manufacturing (ExAM) system [10] for manufacturing metal parts [20] includes a mobile foundry system [12] configured to produce an alloy powder [14] from a feedstock [16], and an additive manufacturing system [18] configured to fabricate a part using the alloy powder [14]. The additive manufacturing system [18] includes a computer system [50] having parts data and machine learning programs in signal communication with a cloud service. The parts data [56] can include material specifications, drawings, process specifications, assembly instructions, and product verification requirements for the part [20]. An expeditionary additive manufacturing (ExAM) method for making metal parts [20] includes the steps of transporting the mobile foundry system [12] and the additive manufacturing system [18] to a desired location; making the alloy powder [14] at the location using the mobile foundry system; and building a part [20] at the location using the additive manufacturing system [18].

An expeditionary additive manufacturing (ExAM) system [10] for manufacturing metal parts [20] includes a mobile foundry system [12] configured to produce an alloy powder [14] from a feedstock [16], and an additive manufacturing system [18] configured to fabricate a part using the alloy powder [14]. The additive manufacturing system [18] includes a computer system [50] having parts data and machine learning programs in signal communication with a cloud service. The parts data [56] can include material specifications, drawings, process specifications, assembly instructions, and product verification requirements for the part [20]. An expeditionary additive manufacturing (ExAM) method for making metal parts [20] includes the steps of transporting the mobile foundry system [12] and the additive manufacturing system [18] to a desired location; making the alloy powder [14] at the location using the mobile foundry system; and building a part [20] at the location using the additive manufacturing system [18].

Disclosed herein are embodiments of methods, devices, and assemblies for processing feedstock materials using microwave plasma processing. Specifically, the feedstock materials disclosed herein pertains to scrap materials, dehydrogenated or non-hydrogenated feed material, and recycled used powder. Microwave plasma processing can be used to spheroidize and remove contaminants. Advantageously, microwave plasma processed feedstock can be used in various applications such as additive manufacturing or powdered metallurgy (PM) applications that require high powder flowability.