What does powder reuse change?

Model fresh Ti-6Al-4V demand, annual cost, oxygen accumulation and working inventory from one defensible mass balance.

Model inputs

Build assumptions

Live

Production

Builds per year

yr⁻¹

Charge per build

Parts + supports

Handling loss

Optimized handling loss

Economics

Virgin powder price

$/kg

Oxygen model

Virgin oxygen

wt%

Pickup per build

wt%

Grade 23 ELI limit

wt%

Grade 5 limit

wt%

Projection horizon

builds

Illustration model, not market data. Confirm material limits and oxygen pickup with your process data.

Annual reuse case

87.5%less fresh powder than once-through

$3.50Mannual purchase saving

2,500 kgfresh powder demand per year

01 / Mass balance

Where one charge goes

The recovered fraction remains in circulation. Fresh top-up replaces only fused powder and handling loss.

20 kgparts + supports

5 kghandling loss

175 kgrecovered

200 kg total charge per build Fresh top-up: 25 kg/build

02 / Annual comparison

Fresh powder demand and cost

100 builds per year · $200/kg virgin powder

Scenario	Fresh powder	Annual cost	Saved vs once-through

03 / Chemistry

Oxygen projection with top-up dilution

Each curve mixes recovered powder after oxygen pickup with virgin top-up before the next build.

04 / Inventory

Working capital tied up in powder

Both cases use the same coverage policy: one full charge plus approximately one month of fresh supply.

Once-through stock20,000 kg

Reuse working inventory408 kg

Inventory released19,592 kg · $3.92M

This is a planning comparison, not a purchasing recommendation. Adjust buffer policy, lot segregation and qualification requirements for your facility.

CSV includes inputs, scenario results, inventory and the full oxygen series.