ADVANCED MATERIALS & PROCESSES | MARCH 2026 22 and lower qualification barriers compared to metal AM. Powder-based metal AM is also witnessing incremental progress through powder reuse, reconditioning, and blending strategies, offering imminent pathways to reduce material waste without disrupting existing production systems. Examples include commercial initiatives by 6K Additive and IperionX to produce AM powders from recycled feedstocks (Fig. 4). Looking ahead, the industrial viability of upcycled feedstock for AM will depend on advances in feedstock characterization, in-process monitoring, and performance-based qualification frameworks. Collaboration between equipment manufacturers, material suppliers, and end users will be essential to translate promising demonstrations into robust production solutions. As these elements mature, material upcycling is expected to evolve from a sustainability-driven initiative into a strategic enabler of resilient, cost- effective additive manufacturing. SUMMARY AND CONCLUDING REMARKS Upcycling is moving from a sustainability concept to an operational strategy, reducing dependence on virgin feedstock while enabling local, closedloop manufacturing. The next phase of scale-up will be driven by practical, performance-based feedstock qualification approaches compatible with production realities. Continued collaboration between academia, industry, and standards organizations will be essential to realizing its full potential. ~AM&P Note: SolidStir is a registered trademark of Enabled Engineering. For more information: Dr. Sweta Baruah, Knoxville, Tennessee, sbaruah@utk.edu, www.linkedin.com/in/swetabaruah/. References 1. R.S. Haridas, et al., SolidStir Technology: A Novel Solid-state Integrated Manufacturing Process for Structural Fabrication, Manufacturing Letters, 40, p 154-158, 2024, doi.org/10.1016/j.mfglet. 2024.05.001. 2. P. Kindermann, et al., Cold Spray Forming: A Novel Approach in Cold Spray Additive Manufacturing of Complex Parts using 3D-printed Polymer Molds, Progress in Additive Manufacturing, 9, p 1567-1578, 2024, doi.org/10.1007/ s40964-023-00521-9. Fig. 4 — Illustrative example of a circular powder supply strategy for metal AM enabled by recycled feedstock and reprocessing pathways. Courtesy of 6K Additive.
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