Powder Technology for Recycling and the Circular Economy

In today’s world, where resource conservation and sustainability are increasingly important, powder technology plays a crucial role in recycling and the circular economy. Whether metallic residues, powder waste from additive manufacturing, filter dusts, or even complex hybrid materials: what was often considered hard-to-recycle waste can be transformed at Fraunhofer IFAM into new, value-added materials and components using powder technology processes. The key advantage: powder technology enables the direct use of recycled materials – even when they are not spherical, fine powders.

Recycling of Metal Powder and Metallic Waste 

We support our customers along the entire process chain – from residual material analysis and powder preparation through to component manufacturing – with tailored solutions:

• Material preparation: Kneaders, mixers, and compounders capable of handling even challenging recycled materials are available. Through targeted sieving, classification, and segregation analysis, we ensure that powders are suitable for subsequent processing.
• Shaping: We use processes such as Metal Injection Molding (MIM), additive processes, extrusion, and Cold Isostatic Pressing (CIP). These methods enable the production of complex geometries and porous structures – even from powders that may not seem optimal at first glance. We also rely on conventional processes such as pressing and sintering.
• Material tailoring: Through re-alloying, we can deliberately adjust the composition of recycled powders.
• Analytics: Comprehensive characterization underpins safe processing. In addition to gas analysis (O/N/H/C/S), we focus on particle characterization (SEM with EDX, laser diffraction, sieve analysis), flowability measurements, bulk and tapped density, as well as thermal analyses (TGA/DSC, hot extraction). For further elemental analyses, we also use complementary methods such as XRF.

Innovative Use of Coarse or Irregular Particles

It is often assumed that only perfectly spherical powders can be recycled. Our expertise shows, however, that coarser or irregular particles can also be efficiently processed via CIP, pressing, and extrusion. This opens up recycling pathways for residual materials that would otherwise be difficult to utilize.

Diverse Fields of Application: Hardmetals, Magnetic Materials, and More 

Our powder technology processes unlock numerous possibilities, such as:

• Reuse of residual powders from titanium and aluminium alloys
• Conversion of cemented carbide grinding waste into new tools
• Use of recycled NdFeB powders in electric motors and generators
• Preparation of metal–polymer composites for the electronics industry
• Use of filter dusts and sludges as a source of critical metals such as Ni, Co, or Cu
• CO2 capture, catalysis, and heat exchanger components enabled by porous structures 

Why Powder Technology Is the Enabler for Sustainable Materials

• Use of recycled materials without energy-intensive remelting
• High tolerance for irregular particle shapes
• New material combinations and designs
• Scalable processes – from lab scale to industrial pilot plant
• Your Partner for Implementing the Circular Economy

Sustainable powder technology is the key to a true circular economy. Fraunhofer IFAM is your partner for the analysis, preparation, and processing of your residual materials. Contact us and let’s turn waste into the materials of the future.

Your partner for implementing the circular economy

Sustainable powder technology is the key to a truly circular economy. Fraunhofer IFAM is your partner for analyzing, preparing, and processing your residual materials. Feel free to contact us and let's work together to transform waste into materials of the future.