As part of a partnership with Siemens Energy, the US company Continuum Powders recycled a total of 16,182 kilograms of nickel waste from a turbine maintenance facility in North Carolina in the last five months of 2024. The resulting material was converted into high-purity metal powder for additive manufacturing using a plasma-based atomization process.
The technology, known as Greyhound M2P, uses plasma beams to break down metallic starting material into ultra-fine powder particles. These powder specifications meet the requirements of demanding industries such as aerospace, defense and energy technology, where nickel-based superalloys are particularly in demand
“This milestone reflects our unwavering commitment to innovation and sustainability,” said Rob Higby, CEO of Continuum Powders. “By prioritizing efficient recycling and high-quality production, we are helping industry leaders reduce their environmental impact and build supply chain resiliency.”
Siemens Energy is pursuing a strategic goal by returning recycled materials to its own supply chain: to establish a closed material loop within manufacturing.
“Our goal is to recycle scrap materials into high-quality metal powders for reuse in additive manufacturing because when we minimize waste and boost circular manufacturing, it makes us a stronger player in the energy sector,” said Rich Voorberg, President of Siemens Energy in North America.
“Our recycling and powder production capabilities prove that innovative solutions can deliver significant environmental and economic value while meeting the most demanding industry requirements,” said Michael Brennen, Sales Director at Continuum Powders.
The collaboration highlights the potential of additive manufacturing when combined with sustainable materials sourcing. Continuous recovery and reuse of industrial waste could become standard practice in metal processing, especially in sectors with high material costs and strict regulatory requirements. For Continuum, the project also marks progress toward scalable, resource-efficient powder production—an increasingly relevant factor in light of ongoing global supply chain challenges.
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