The LCA analyzed three different nickel powder production methods
A new independent study conducted by researchers at Oregon State University has confirmed the dramatic environmental benefits of Continuum Powders’ advanced metal recycling technology. The Life Cycle Assessment (LCA) of nickel powder production found that by utilizing Continuum’s Melt-to-Powder (M2P) technology, carbon emissions were reduced by 99.7% compared to conventional virgin nickel powder production.
Nickel powder is a critical material for aerospace, energy, and defense industries, but traditional production methods rely on energy-intensive virgin metal extraction from mines and ores. Other powder producers often use pre-alloyed ingots or wire feedstock, which require multiple remelting steps, adding to the carbon footprint. In contrast, Continuum Powders’ Greyhound M2P plasma atomization process directly converts 100% scrap material into high-quality metal powder without prior remelting or chemical adjustments. By eliminating these additional processing stages, the M2P technology significantly reduces energy consumption and reinforces the advantages of a truly circular metal economy.
The LCA conducted by Oregon State University’s Industrial Sustainability Laboratory in the School of Mechanical, Industrial, and Manufacturing Engineering, analyzed three different nickel powder production methods. The findings showed that the conventional approach uses 100% virgin nickel, which contributes to 96% of the global warming potential (GWP) in the production process. However, when using 100% recycled nickel feedstock through Continuum’s Houston facility, carbon emissions were cut by 99.7%.
“This study confirms what we’ve known—sustainable metal powder production is not just an aspiration; it’s a reality,” said Sunil Badwe, Ph.D., Chief Technology Officer at Continuum Powders. “By transitioning from virgin to recycled metal feedstocks, we’re proving that sustainability and high-performance manufacturing can go hand in hand. The results of this LCA study validate our commitment to reducing emissions while delivering high-quality powder solutions. With 99.7% reduction in carbon emissions than the conventional gas atomizing, Continuum’s powder manufacturing is the most environmentally sustainable method available today, to our best knowledge.”
Haapala’s insights underscore the broader implications of sustainable metal powder production, particularly as industries seek solutions to reduce their carbon footprint.
With increasing pressure to reduce industrial carbon emissions, the results of this study highlight the growing importance of sustainable manufacturing solutions. By adopting metal powders produced from 100% recycled feedstock, advanced manufacturers can significantly cut emissions, enhance supply chain resilience, and reduce dependency on scarce raw materials.
The results of this LCA will further cement Continuum Powders’ position as an advocate for sustainable manufacturing in the industry.
Looking for a job in the AM industry or hiring new talent? You can post job opportunities on 3D ADEPT Media for free or explore openings via our job board. Stay connected by following us on Facebook, Twitter, LinkedIn & Instagram, and subscribe to our weekly newsletter for the latest updates. Have a story to share or want to be featured in our next digital magazine issue? Send it to editor@3dadept.com !
