During the first reporting period, REPAM established the technical basis for its circular additive manufacturing approach. The consortium defined requirements for additive manufacturing and atomisation processes, including the data, sensor and modelling needs required to compare virgin, recycled, reused and conditioned feedstocks.
Process modelling work has been initiated for gas atomisation and additive manufacturing. Computational models have been developed to describe melt flow, thermal behaviour, particle formation and process conditions. These models provide a basis for understanding powder production and additive manufacturing behaviour and will support later optimisation of process parameters. In parallel, AI and data-driven tools have been developed for optimisation of gas atomisation processes, to maximise the percentage of powder with the right sizes for a given application.
Significant progress has also been made on monitoring and sensor integration. Monitoring approaches have been developed and tested for powder bed fusion, gas atomisation and centrifugal atomisation. These include recoater force monitoring, moisture monitoring, hyperspectral imaging, high-speed imaging, thermal imaging, acoustic and vibration monitoring. The purpose is to generate reliable process data that can be used for model validation, process optimisation and eventually real-time control with input from sensors.
Data-driven tools have been developed for AM process analysis and optimisation. Early models and software tools have been prepared to interpret powder, process and sensor data, including approaches for powder-bed monitoring and prediction of relevant part or powder properties. These tools are intended to help identify process windows and reduce waste caused by unstable or failed builds.
The project has also advanced practical recycling routes. Titanium and aluminium machining chips have been collected, cleaned, crushed and processed into feedstock for wire production. Swarf-derived powder-cored wires have been manufactured and tested in downstream deposition trials, demonstrating the feasibility of converting machining waste into additive manufacturing feedstock. Initial system technology for additive manufacturing has also been implemented, including directed energy deposition and powder bed fusion process setups, sensor integration and beam-shaping related developments.
Assessment work has started in parallel. Environmental life-cycle assessment, socio-economic assessment and health and safety assessment methodologies have been defined, including scenarios for comparing conventional production, classic additive manufacturing and REPAM routes based on recycled or reconditioned materials. Standardisation and skills needs have also been mapped, with initial recommendations related to feedstock reuse, recycling, monitoring, data reporting and safe handling of additive manufacturing materials.
