Metal Recycling in 3D Printing: How Continuum Powders Reduces Waste and Energy Use – Interview with Rob Higby

Continuum Powders produces metal powders for additive manufacturing by repurposing reclaimed high-performance alloys into high-quality feedstock. Instead of relying on virgin materials, the company repurposes scrap metal and end-of-life components, creating powders that meet the stringent demands of industries like aerospace, energy, and defense. This approach not only conserves valuable resources but also aligns with the growing need for sustainable and efficient manufacturing solutions. In an interview with 3Druck.com, CEO Rob Higby discusses the role of additive manufacturing in sustainability, metal recycling, and technological advancements across various industries.

At the center of its operations is Greyhound M2P, a plasma-based Melt-to-Powder process that converts reclaimed metal into fine powders optimized for 3D printing. By eliminating multiple refining steps, this method reduces energy consumption and emissions while maintaining material integrity. The resulting powders meet industry standards, ensuring they can be used in demanding applications without performance trade-offs.

By adopting a circular approach to metal production, Continuum Powders enables manufacturers to optimize material usage while maintaining high-performance standards. The Greyhound M2P system is alloy-agnostic, allowing for the production of custom powders tailored to specific application needs. This process minimizes resource waste and supports long-term supply chain stability, an increasingly important factor in additive manufacturing.

With sustainability gaining priority across industries, the demand for efficient material solutions continues to grow. Continuum Powders’ Melt-to-Powder approach provides a reliable source of metal powders while helping customers meet environmental goals without compromising on quality or performance.

Interview with Rob Higby

In an interview with 3Druck.com, Continuum Powders CEO Rob Higby explains how additive manufacturing reduces waste and energy use, highlighting Continuum Powders’ Melt-to-Powder process for recycling metal into high-quality powders. He also discusses key innovations like multi-laser LPBF systems and binder jetting, emphasizing their impact on aerospace, healthcare, and energy.

In your view, what role does additive manufacturing play in shaping the future of sustainable production in the manufacturing industry?

Additive manufacturing is changing how we think about sustainability in manufacturing. Traditional methods like casting and forging waste a lot of material and require a huge amount of energy. Additive manufacturing does the opposite. It builds parts with precision, reducing scrap and using energy more efficiently.

At Continuum Powders, sustainability is not just part of what we do—it’s the foundation. Our Melt-to-Powder (M2P) technology takes scrap metal and end-of-life components and turns them into high-quality metal powders. Instead of throwing valuable materials away, we keep them in use. This helps our customers lower their environmental impact without sacrificing quality or performance.

As industries look for ways to cut emissions and waste, additive manufacturing will be a key tool to help them meet those goals—without driving up costs or slowing down production.

How does your “Melt-to-Powder” process differ from traditional methods of metal powder production for additive manufacturing?

Most metal powder still comes from virgin materials, which means mining, refining, and melting—an expensive, energy-heavy process that generates a lot of emissions. Our M2P process changes that.

Instead of starting from scratch, we take scrap metal and end-of-life parts and turn them into fresh powder in a single step. Our plasma-based process cuts out multiple refining stages, reducing energy use and emissions while keeping high-quality materials in circulation.

But it’s not just about sustainability. Our powders match or exceed the performance of virgin materials, so manufacturers don’t have to choose between sustainability and quality. They get both. This approach helps companies cut waste, strengthen their supply chains, and move toward a more sustainable future.

Additive manufacturing has advanced significantly in recent years. Which innovations or breakthroughs do you consider particularly transformative?

Additive manufacturing has taken huge steps forward in the past few years. Three key innovations stand out.

First, multi-laser LPBF systems are making additive manufacturing more scalable. With multiple lasers working at once, these systems print parts faster without losing precision. That means manufacturers can now make high-performance metal components at larger production volumes.

Second, binder jetting is changing how companies make metal parts. Many manufacturers are moving away from casting and forging, choosing binder jetting instead. It lowers costs, speeds up production, and makes more complex designs possible.

Second, multi-laser LPBF systems are making additive manufacturing more scalable. With multiple lasers working at once, these systems print parts faster without losing precision. That means manufacturers can now make high-performance metal components at larger production volumes.

Third, closed-loop metal recycling is becoming standard. Instead of relying only on new raw materials, more companies are recycling old parts and turning them back into powder. This reduces waste, strengthens supply chains, and supports a circular economy.

We’re already seeing aerospace and energy companies adopt these technologies. This isn’t a future trend—it’s happening now and changing how industries operate.

Looking ahead, how do you see additive manufacturing influencing the development of critical industries such as aerospace, healthcare, and energy in the coming years?

Additive manufacturing is already transforming these industries, and its role will only grow as materials and technology improve.

In aerospace, AM is making aircraft lighter and more fuel-efficient. Advanced alloys like Ni718, M247, and Ti64 are in high demand for hypersonic and space applications, where materials need to withstand extreme conditions. These innovations allow manufacturers to create stronger, more efficient propulsion systems that wouldn’t be possible with traditional methods.

In healthcare, AM is revolutionizing medical implants and surgical tools. Titanium-based alloys make implants custom-fit, stronger, and lighter, which improves patient outcomes and speeds up production. Hospitals and medical device companies are using AM to create patient-specific parts faster and more efficiently than ever before.

In energy, AM is driving the shift toward renewable energy and advanced power systems. Turbine components, as well as heat exchangers for hydrogen and nuclear applications, are becoming more efficient thanks to additive’s ability to create complex, optimized designs. As the world moves away from fossil fuels, AM will play a big role in making cleaner, more scalable energy solutions.

Industries that have relied on casting and forging for decades are now embracing additive manufacturing as a mainstream method. Companies that invest in AM today will be the ones shaping the future. At Continuum Powders, we’re proud to provide the materials that make that future possible.

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