Reuse of 316L stainless steel towards zero-waste laser powder bed fusion

Aiming to enhance the adoption of sustainable practices in the Italian manufacturing sector, this study investigated the application of powder reuse in laser powder bed fusion (L-PBF) processes. Within the “Made in Italy-Circular and Sustainable” (MICS) Extended Partnership, backed by the European Union Next-GenerationEU, an alternative reuse strategy was studied through 316L stainless steel specimens fabricated from powder subjected to five and ten reuse cycles. Compared with virgin powder data, the characterization performed through particle size analysis, hardness, and tensile testing shows that ten reuse cycles do not affect part or powder quality significantly. The results support extended powder reuse potential, highlighting how LPBF can facilitate zero-waste production and foster Italy’s transition toward greener and circular practices, improving the competitiveness of made-in-Italy products while minimizing both resource consumption and material waste.