Additive Manufacturing worked example

Powder Reuse Savings with reusable powder mass of 23 kg: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop reusable powder mass to 23 kg, then walk the calculation through step by step. Estimate dollar savings from reusing qualified powder instead of charging every build at virgin powder cost.

The inputs for this scenario

  • Reusable powder mass: 23 kg (the input this scenario stresses; the baseline uses 45)
  • Virgin powder value: 72 $ / kg (held at the documented default)
  • Sieving/handling cost: 260 $ (held at the documented default)
  • Qualification overhead: 180 $ (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Virgin powder value avoided = reusable powder mass × virgin powder value.
  • Net reuse savings works out to 2,096 $ at these inputs, and this is the headline figure for the scenario.
  • Savings per kg reused works out to 91.13 $ / kg at these inputs.
  • Virgin powder value avoided works out to 1,656 $ at these inputs.
  • Reuse handling burden works out to 440 $ at these inputs.

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 43.04% below the baseline at 2,096 $.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to reusable powder mass, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. It is a per-batch snapshot; it does not model property degradation over many reuse cycles, which eventually forces disposal regardless of the dollar math.

Results at a glance

  • Net reuse savings: 2,096 $ (headline result)
  • Savings per kg reused: 91.13 $ / kg
  • Virgin powder value avoided: 1,656 $
  • Reuse handling burden: 440 $

Run it with your numbers

  • To rerun this with your own numbers, open the live Powder Reuse Savings calculator, set reusable powder mass to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.