Additive Manufacturing worked example

Powder Reuse Savings with reusable powder mass of 110 kg: a worked example

This scenario runs the powder reuse savings calculation on the strong side: reusable powder mass of 110 kg, with every other input held at its documented default. a service bureau owner or materials engineer needs to quantify the benefit of a powder reuse program

The inputs for this scenario

  • Reusable powder mass: 110 kg (raised for this scenario; the documented default is 45)
  • Virgin powder value: 72 $ / kg (unchanged)
  • Sieving/handling cost: 260 $ (unchanged)
  • Qualification overhead: 180 $ (unchanged)

Working through the calculation

  • Applying the documented formula (Virgin powder value avoided = reusable powder mass × virgin powder value) to the inputs above produces each figure below.
  • At this operating point the engine returns 8,360 $ for net reuse savings, the number this scenario is built around.
  • At this operating point the engine returns 76 $ / kg for savings per kg reused.
  • At this operating point the engine returns 7,920 $ for virgin powder value avoided.
  • At this operating point the engine returns 440 $ for reuse handling burden.

How this compares with the baseline

  • Against the tool's baseline example, where reusable powder mass sits at 45 kg and the headline result is 3,680 $, this scenario comes in 127% above the baseline at 8,360 $.
  • Use it when building the business case for a reclaim program, comparing reuse against buying virgin, or setting an internal transfer price for recycled powder. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Net reuse savings: 8,360 $ (headline result)
  • Savings per kg reused: 76 $ / kg
  • Virgin powder value avoided: 7,920 $
  • Reuse handling burden: 440 $

Run it with your numbers

  • Every input above is editable in the live Powder Reuse Savings calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.