Upcycling of Copper Scrap into High-Quality Powder for Additive Manufacturing: Processing, Characterization, and Sustainability Assessment
Authors
Mattia Cabrioli 1, María Silva Colmenero 1, Sepideh Gholamzadeh 1, Matteo Vanazzi 1, Sasan Amirabdollahian 2, Matteo Perini 2, Wojciech Łacisz 3 and Bartosz Kalicki 3
Abstract
Copper is a critical material for energy transition and green technologies, making its sustainable use increasingly important. Its superior thermal and electrical conductivity make it highly well-suited for additive manufacturing (AM). In this study, copper sourced from offshore electrical cables was upcycled to produce high-quality metal powder for AM. The scrap was processed to separate the metal from plastic and rubber, then refined through ultrasonic atomization, achieving a purity of ~99.5% wt.% with minimal impurities. Characterization demonstrated good flowability, apparent and tap densities, and a well-distributed particle size. To assess its performance in AM, the powder was printed using Directed Energy Deposition (DED) with a laser beam, confirming its high printability and compatibility with the base material. Finally, a comparative Life Cycle Assessment (LCA) revealeda significant environmental advantage of the recycling-based process over conventional mining, reducing global warming potential by more than 70%. These findings highlight the importance of feedstock origin in AM sustainability and support the adoption of circular economy strategies to lower the environmental footprint of advanced manufacturing
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