Additive Manufacturing worked example
Powder Usage at 99% powder recovery efficiency: a worked example
What does the result look like when powder recovery efficiency reaches 99%? The full calculation is worked below with real intermediate numbers. an additive manufacturing engineer needs powder mass before releasing a powder bed build
The inputs for this scenario
- Build quantity: 120 parts (unchanged)
- Powder required per part: 0.06 kg / part (unchanged)
- Powder recovery efficiency: 99 % (raised for this scenario; the documented default is 88)
Working through the calculation
- Applying the documented formula (Theoretical powder = build quantity × powder required per part) to the inputs above produces each figure below.
- At this operating point the engine returns 6.67 kg for powder required, the number this scenario is built around.
- At this operating point the engine returns 6.6 kg for net fused/cake powder.
- At this operating point the engine returns 0.07 kg for recovery and handling loss.
- At this operating point the engine returns 99 % for powder recovery efficiency.
How this compares with the baseline
- Against the tool's baseline example, where powder recovery efficiency sits at 88% and the headline result is 7.5 kg, this scenario comes in 11.11% below the baseline at 6.67 kg.
- A figure at this level is achievable when powder recovery efficiency is genuinely sustained, not just peaked for a shift. Recovery efficiency varies by material, sieve, and machine; a value measured on one alloy and sieve setup will not transfer cleanly to another.
Results at a glance
- Powder required: 6.67 kg (headline result)
- Net fused/cake powder: 6.6 kg
- Recovery and handling loss: 0.07 kg
- Powder recovery efficiency: 99 %
Run it with your numbers
- Every input above is editable in the live Powder Usage calculator, which recalculates instantly and can be shared with the inputs intact.
Last reviewed 2026-05-12.