Provided is a method for manufacturing material powder for metal laminating modelling, in which a virgin material is manufactured based on the particle size distribution of the virgin material being an unused material powder, and the fluidity of an unsintered reused material after the virgin material is reused a predetermined number of times by a metal laminating modelling device, so that the particle size distribution of the virgin material corresponds to the fluidity of the reused material that is equal to or greater than a predetermined standard value. Silica particles may be added to the virgin material.

The embodiments disclosed herein are directed to systems and methods for manufacturing recycled copper alloy powder particles from used or deficient copper alloy powder particles. In some embodiments, used copper alloy powder particles comprising near-surface oxygen are introduced into a microwave plasma torch. In some embodiments, the used copper alloy powder particles are heated within the microwave plasma torch to at least partially remove the oxygen and form recycled copper alloy powder particles, without melting the used copper alloy powder particles.

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, recycled used powder, and gas atomized powders. 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.

A novel material size reducing and storage device system comprising of a composting system and a three-dimensional (3D) printing system is disclosed. The compost system is configured to facilitate material size reduction of compostable material. The 3D printing system is configured to facilitate 3D printing of one or more objects using material that have been reduced to a predetermined size.

A novel material size reducing and storage device system comprising of a composting system and a three-dimensional (3D) printing system is disclosed. The compost system is configured to facilitate material size reduction of compostable material. The 3D printing system is configured to facilitate 3D printing of one or more objects using material that have been reduced to a predetermined size.

Disclosed herein are systems and methods for synthesis of spheroidized metal or metal alloy powders using microwave plasma processing. In some embodiments, the metal or metal alloy may comprise a highly ductile, soft, and/or malleable metal or metal alloy such that machining of the metal or metal alloy is difficult or impossible. In some embodiments, a volatile material is dispersed within the metal or metal alloy feedstock to enable machining and pre-processing of the feedstock. In some embodiments, the dispersed volatile material alters the physical properties of the feedstock, such that the metal or metal alloy, which is difficult to machine due to high ductility, softness, and/or malleability, is easily machined in a pre-processing step. In some embodiments, the pre-processed feedstock, can be fed into a plasma processing apparatus. In some embodiments, the volatile material dispersed within the feedstock material may be vaporized upon exposure to the microwave plasma apparatus. In some embodiments, plasma processing of the pre-processed feedstock material may synthesize pure, spheroidized metal or metal alloy particles, with substantially no contamination of the volatile material ion the final product.

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

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