Continuum Powders introduces Direct Powder Feeder for closed-loop metal powder cycles

Continuum Powders has introduced the Direct Powder Feeder (DPF), a unit that routes residual fractions from additive manufacturing back into metal powder atomization without intermediate steps. The goal is a closed material loop: non-utilizable sieve fractions—such as oversize or undersize particles after LPBF or DED builds—are directly re-atomized instead of being consolidated first or processed externally. For reactive alloys like titanium, the approach is particularly relevant because oxygen pickup, particle morphology, and flow characteristics are decisive for part quality.

Technically, the DPF ties the return stream into the atomizer’s feed. This eliminates puck/consolidation stages that were previously necessary to make residual powder usable again. Re-atomization restores the desired size distribution and sphericity, shortens lead times, and limits material losses. In parallel, Continuum continues to operate dedicated consolidation for external jobs, but positions the DPF as a faster route to return internally generated residual quantities to the feedstock.

Rizk Ghafari COO of Continuum Powders, hailed the development as a pivotal step for the company and the industry: “This is a game changer — it’s a major milestone in powder production.  By reclaiming material that would otherwise be lost and returning it to the feedstock stream without compromising quality, we’re improving efficiency, reducing costs, and setting a new benchmark for circular manufacturing in advanced metals.”

“From the start, our goal has been to engineer systems that cut waste and keep valuable material in circulation,” said David Vega, Manufacturing Manager, and Paul Meese, Technical Fellow, in a joint statement. “The Direct Powder Feeder advances that mission by simplifying how reclaimed powder is fed back into our process—helping customers meet production demands while maximizing powder quality and sustainability.”

With the DPF and accompanying consolidation, Continuum aims to increase powder yield and supply chain resilience. From a user perspective, the benefits are clear: less waste, faster re-qualification of feedstock, and consistent powder properties over multiple cycles. This brings a data-driven, circular operation in metal AM closer, without bypassing established testing and certification requirements.