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The ToZero (Towards Zero Waste in Aluminum BiW Manufacturing) project has demonstrated that recycled automotive aluminium scrap can be transformed into powder suitable for laser powder bed fusion (LPBF), supporting efforts to increase the use of recycled materials in additive manufacturing.
{alcircleadd}Supported under Italy's Accordi per l'Innovazione programme, the project involved Valland, Politecnico di Torino, Politecnico di Bari and the Fontana Group, with Valland leading the additive manufacturing phase.
The company developed LPBF processing parameters for recycled AA5083 aluminium powder and used the material to manufacture a structural automotive connection node known as the "Voletto". According to the project team, the recycled alloy was printed without hot cracking, while the finished component met targeted mechanical strength and ductility requirements.
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Topology optimisation reduced the component's weight from 1.68 kg towards a target of 0.8 kg. A life-cycle assessment carried out in accordance with ISO 14040/44 standards found that the optimised manufacturing process lowered the part's carbon footprint by approximately 73 per cent.
Despite the environmental gains, Valland said productivity remains a challenge. The company noted that recycled AA5083 prints significantly slower than the widely used AlSi10Mg alloy, making print speed one of the key barriers to large-scale industrial adoption.
The project reflects a wider industry trend towards producing additive manufacturing feedstock from recycled metal. Companies such as 6K Additive and Continuum Powders are also developing technologies to convert reclaimed industrial metal into high-quality powders for advanced manufacturing applications.
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