In metal powder-based additive manufacturing, up to 95% of the powder deposited during printing remains unused, representing both a significant cost and potential material waste. This residual powder can experience physical and chemical changes through repeated thermal cycling and exposure to process conditions, affecting particle size distribution, morphology, and flow characteristics essential for consistent printing quality.

The core challenge lies in efficiently recovering and reconditioning residual powder while maintaining its critical material properties within specification limits for reuse.

This page brings together solutions from recent research—including closed-loop pneumatic recovery systems, selective powder deposition techniques, vibratory filtering apparatus, and in-situ material regeneration methods. These and other approaches focus on maximizing powder recyclability while ensuring consistent print quality and preventing cross-contamination.

1. Comparative Studies of Three-Dimensional Complex Flow Field Designs in a Proton Exchange Membrane Hydrogen Fuel Cell

dilyan gavrailov, silviya boycheva - Multidisciplinary Digital Publishing Institute, 2025

The performance and durability of proton-exchange membrane fuel cells (PEMFCs) are dependent on flow, humidifying water, outgoing water management. Unlike conventional flow fields with linear channels, the complex 3D field—featuring repeating baffles along channel, known as baffle design—induces a micro-scale interface flux between gas diffusion layer (GDL) fields. Thus, an intensive oxygen is created that removes excess from GDL, thereby improving cell efficiency. Another approach for channel design Turing field, which resembles organization fluid flows in natural objects such leaves, lungs, blood system. This enhances distribution inlet significantly compared traditional designs. present study aims to combine advantages both field designs provide model investigations influence mixed efficiency PEMFCs. It was established achieves highest electrode current density 1.2 A/cm2, outperforming other Specifically, it 20% improvement over design, reaching 1.0 A/cm2 generating three times more than delivers 0.4 A/cm2. In contrast, serpentine exhibit lowest density. provides better utiliz... Read More

2. Mixed Wettability Influence on Water Droplet Behaviour in a PEM Fuel Cell Channel

simona silvia merola, christian antetomaso, adrian irimescu, 2025

<div class="section abstract"><div class="htmlview paragraph">The utilization of hydrogen in low-temperature Proton Exchange Membrane Fuel Cells (PEMFCs) stands out as a compelling prospect for driving widespread shift towards green industry practices. Despite significant advancements, comprehensive understanding water behaviour and dynamics within PEMFCs remains crucial their extensive integration propulsion applications. Striking delicate balance between flooding drying conditions poses challenge achieving stable efficient PEMFC operation. In this study, preliminary experimental investigation was conducted focusing on carbon-paper Gas Diffusion Layer (GDL) gas channel walls. The static, advancing receding contact angles were measured utilized boundary simulations. influence membrane humidity also examined during the campaign. 3D CFD simulations performed straight portion with selected domain length 5 mm section 1x1 mm. Two classes droplets (0.05 mm<sup>3</sup> 0.075 mm<sup>3</sup>) deposited middle double GDL wall. To account difference angles, r... Read More

3. Dual Direction Flow Restrictor with Expandable Slotted Flowbody and Debris Removal Mechanism

HONEYWELL INTERNATIONAL INC, 2025

Dual direction flow restrictor that prevents debris from clogging the orifice while allowing easy removal of debris introduced during additive manufacturing. The flow restrictor has two flowbody sections, one with slots and a larger diameter section that expands the other section when coupled. This allows debris to be easily removed from the expanded section during manufacturing, preventing clogging of the orifice. In the assembled flow restrictor, the smaller section with slots is received inside the larger section's counterbore.

US12276292B2-patent-drawing

4. Vacuum Chamber Device with Multi-Axis Movable Component Carrier and Tubular Supply Lines for Powder Removal from 3D-Printed Components

ACTECH GMBH, 2025

A device for cleaning 3D-printed components from adhering powder particles without manual intervention. The device uses a vacuum chamber with a movable component carrier that can be inserted and removed through a pressure-tight door. Inside the chamber, a platform moves in multiple axes to receive the 3D-printed part. Tubular supply lines in the chamber walls generate a volumetric flow when closed. The component carrier and chamber are connected to a negative pressure system. This vacuum pulls the adhering powder particles off the component as it moves inside the chamber. The removed powder is collected in hoppers and sent to a separation system.

5. Recyclable 3D Printing Resin System with Reactive Particulate Reformulation

CARBON INC, 2025

Recyclable resins for 3D printing that can be reground and remade into new 3D printing resins. The recycling process involves grinding or melting printed parts to make a reactive particulate material. This is mixed with additional blocking agents and diluents, then heated to reform a homogeneous solution. Additional photoinitiator, light absorber, etc. are added to make a new printable resin from the recycled material. This allows closed loop recycling of 3D printed objects.

6. Process for Detaching Ultrafine Particles from Atomized Powder Using Liquid Contact and Energy Application

GENERAL ELECTRIC CO, 2025

A process for removing ultrafine particles from atomized powder to improve flowability and other properties of the powder. The process involves contacting the atomized powder with a removal liquid, adding energy to the mixture to detach the ultrafine particles, and separating the removal liquid and detached ultrafine particles from the fine particles. This allows selectively removing the ultrafine particles without significantly impacting the fine particles. The separated ultrafine particles can be recycled back into the process. The resulting powder has improved flowability and other properties compared to the initial atomized powder.

US2025114797A1-patent-drawing

7. Guided Water Percolation in 3D-Printed Gas Diffusion Layers for Polymer Electrolyte Fuel Cells

tim dorenkamp, ambra zaccarelli, felix n buchi - American Chemical Society, 2025

The accumulation of liquid water in the gas diffusion layer (GDL) and associated clogging reactant pathways are limiting factors for performance polymer electrolyte fuel cells (PEFC). design manufacturing GDLs with a deterministic pore space have potential to accelerate development next-generation PEFC an optimized balance between supply product removal. In this study, we explore tailored structures obtained from carbonization 3D-printed precursor. Three different GDL designs investigated by using operando X-ray radiography subsequent tomography track pathways. results confirm effectiveness designed features terms controlled percolation reveal trend toward vapor phase transport rather than away catalyst interface along strong convective flow within highly porous ordered structures.

8. Numerical study of a three-dimensional ramp flow field for proton exchange membrane fuel cells (PEMFC)

yong wang, jianfeng hou, yichao li - SAGE Publishing, 2025

Proton Exchange Membrane Fuel Cells (PEMFCs) are considered a crucial technology for mitigating resource limitations and addressing environmental challenges. To improve the output power mass transfer characteristics of PEMFCs, this study developed three-dimensional (3D) model PEMFC with wedge-shaped flow field plate using computational fluid dynamics (CFD) methods. This focused on analyzing behavior thermal management reactants, as well investigating water removal capacity across different angular channel configurations. The results indicated that air intake modes combined channels affected within fuel cell. performance was most significantly when reaction gases flowed convectively. At tilt angle 18° voltage 0.25 V, maximum current density reached 1.9547 A/cm 2 , representing 24% increase compared to conventional parallel channel. Under these conditions, reactive were more uniformly distributed PEMFC. demonstrated new in generates high densities at larger angles lower voltages, improving oxygen distribution facilitating efficient liquid removal.

9. Method for Powder Capture in Additively Manufactured Parts via Removable Membrane-Integrated Caps

GM GLOBAL TECHNOLOGY OPERATIONS LLC, 2025

A method for capturing excess powder from interior passages of additively manufactured parts using removable powder capture caps. The caps are designed with thin membranes that attach to the interior walls of the part during printing. After completion, the caps trap excess powder inside the part. To remove the caps, a tool engages a socket in the cap and twists it until the membrane breaks, allowing access to the powder.

US2025108436A1-patent-drawing

10. Metal Object Fabrication via Inkjet Binder Printing and Selective Metal Powder Deposition

IMPOSSIBLE OBJECTS INC, 2025

3D printing of metal objects using inkjet printing and selective powder deposition. The process involves printing a binder solution onto a substrate to create the object's shape layer by layer. Each layer is then coated with a metal powder. The excess powder is removed, leaving the metal selectively deposited in the printed shape. Challenges like oxidation of metal powders during melting are addressed using fluxes or melting in reducing atmospheres.

11. Method for Calculating Powder Requirement in Multi-Object 3D Printing Using Volume and Recycling Ratio Analysis

SIEMENS INDUSTRY SOFTWARE LTD, 2025

Determining the exact amount of powder needed to 3D print a single object in a multi-object print job. This helps optimize powder usage and reduce waste when printing multiple objects together. The method involves calculating the volume of the printed object's outer layer (dilated object) based on the object's shape and the powder layer thickness. It also calculates the volumes of unused powder in the no-build and interstitial areas. Then, it determines the total lost powder based on recycling ratio and the calculated volumes. Finally, it calculates the required powder for the object by adding the used powder from the dilated object and the lost powder contribution.

12. 3D Printing Powder Removal System with Blade and Coordinated Vacuum Nozzles

SAKUU CORP, 2025

A powder removal system for 3D printing that effectively cleans the build platform without disturbing the printed part. The system has a blade to scrape excess powder from between layers without touching the part. Edge and central vacuum nozzles move with the blade to collect scraped powder without disturbing powder on adjacent areas. This allows precise removal of powder between layers without damaging the printed part.

US12263639B2-patent-drawing

13. Capillary Transport Analysis in Macro-Homogeneous Diffusion Media of PEM Fuel Cells

carmine marra, federico croci, stefano fontanesi, 2025

<div class="section abstract"><div class="htmlview paragraph">The interplay of electrochemistry, two-phase flow, and heat transfer generates complex transport phenomena within the porous materials fuel cells that are not yet fully understood. This lack comprehensive understanding complicates modeling liquid water transport, which is critical because hydration polymer electrolyte membrane significantly impacts cell performance. The mechanisms in media can be explained by capillary force, hydraulic permeation gravity effects, as well condensation evaporation. In general, mainly driven while body forces, such gravity, do affect its momentum. Due to limited experimental data on pressure saturation gas diffusion media, Leverett approach has been widely used for PEMFCs. a polynomial fitting imbibition unconsolidated sand packs. nature, this may accurately predict media. Fuel GDM materials, naturally hydrophilic, typically coated with nonwetting like polytetrafluoroethylene create hydrophobic surfaces pores. resulting nature intermediate wettability due coexistence hydrophilic p... Read More

14. Chain-Link Powder Removal Tool for Additive Manufacturing with Internal Passage Access

GM Global Technology Operations LLC, 2025

Creating a powder removal tool during additive manufacturing that can easily access and remove excess powder from inside complex parts with intricate internal passages. The tool is designed as a chain-like structure of interconnected links that can be simultaneously printed alongside the part. After completion, the tool is removed, forcing the powder out of the internal passages. Additional techniques like robotic appendages, vibration, air blasting, or media blasting can further clear remaining powder.

15. Metal Powder for Additive Manufacturing with Controlled Oxide Film Thickness and Oxygen Content

Proterial, Ltd., 2025

Reusable metal powder for additive manufacturing that enables stable modeling and defect reduction when recycled. The powder contains an oxide film on the surface, with 0.015-0.106% oxygen content and a maximum oxide film thickness of 200 nm. This oxide layer reduces spattering during melting and prevents defects in recycled powder. The powder is reused in additive manufacturing by repeating melting and solidification steps. The oxygen level and oxide film thickness limits prevent oxide expansion and cracking issues in recycled powder.

16. Robotic Depowdering System with Gripping Robot, Blowing Nozzle, and Air Curtain Containment

AZOTH INC., 2025

Automated powder removal from additively manufactured parts using a robotic depowdering system. The system has a depowdering station with a robot that grips the part, a nozzle to blow excess powder off, and a blower with an air curtain to contain the powder. This eliminates manual depowdering and allows automated transfer from the printing to sintering furnace.

US20250083235A1-patent-drawing

17. Automated Depowdering and Extraction System with Linear Actuator and Sliding Perforated Plate Mechanism

Dei Holding LTD, 2025

Automated system for depowdering and extracting 3D printed parts to simplify and streamline the post-processing steps. The system uses a removable container mounted on a linear actuator to raise and lower the printed layers. An internal apparatus with a sliding perforated plate depowders the layers. A gripper extracts the parts. This allows automated, layer-by-layer depowdering and part removal without manual intervention. The container can be swapped between print jobs.

18. Recycling Device with Heated Screen Hopper and Rotating Cutter for FDM 3D Printing Waste Processing

Shared Intelligent Equipment Co., Ltd., KOCEL INTELLIGENT EQUIPMENT CO LTD, 2024

A recycling device for FDM 3D printing waste that can crush, melt, and granulate the waste material to regenerate new printing filament. The device has a hopper with a heated screen to chop the waste. The chopped material falls into a melting extruder and is extruded as filament. A granulating device with a rotating cutter cuts the filament into granules that are collected. This allows recycling and reusing FDM printing waste from each stage of the printing process to reduce material waste and costs.

19. Recycling System for Converting Heterogeneous Waste into 3D Printing Feedstock with Adaptive Process Parameter Adjustment

HITACHI LTD, 2024

System for recycling waste materials into 3D printing feedstock with stable quality, enabling recycling of heterogeneous waste materials containing various components. The system generates manufacturing parameters for the recycled materials and device settings to compensate for variability in the waste materials. It analyzes the physical properties of each waste material batch and adjusts the 3D printing process parameters and device settings accordingly. This allows using recycled materials with varying properties in additive manufacturing while mitigating issues like warping and shrinkage.

20. Additive Manufacturing System with Closed Gastight Material Handling and Integrated Powder Blending

General Electric Company, 2024

Additive manufacturing system with closed material handling to improve efficiency, quality, and safety compared to manual loading and unloading. The system has separate powder and liquid material handling systems that connect to the additive manufacturing machine. Powder is transferred gastight from a drum to the powder system, then to the machine. Liquid materials like binders and cleaners are similarly transferred gastight. This prevents exposure to oxygen and contamination. The machine can also receive blended powder from a sieve that mixes virgin and recovered powder. The closed handling reduces time, improves efficacy, and increases safety for reactive materials.

21. Device with Serial Powder Collection Chambers and Automated Sieving for Continuous Metal Powder Recovery in SLM 3D Printing

22. Recycling Method for Spherical Titanium Powder via Hydrogen-Atmosphere Grinding and Deoxidation

23. Powder Recycling Mechanism with Divided Collection Ports and Detachable Screens for 3D Printers

24. Powder Circulation System with Automated Recycling and Integrated Device Connectivity for 3D Printing

25. 3D Printing Powder Recovery Apparatus with Residual Material Detection and Movable Starting Plate Mechanism

Various methods of recovering remaining powder are demonstrated by the patents included here. Using gravity or closed-loop systems for effective powder recovery, isolating wasted powders for focused regeneration, and enhancing powder flow with humidified air are a few of these methods.

Get Full Report

Access our comprehensive collection of 140 documents related to this technology