Recycled Aluminum Powder 3D Printing Technology and Its Application in Automotive Components

Abstract

The automotive industry is increasingly moving toward lighter and more sustainable manufacturing practices to improve fuel efficiency and limit environmental impact. Aluminum alloys play a vital role in this transformation due to their superior strength-to-weight ratio and recyclability. In recent years, powder-based additive manufacturing (3D printing) has emerged as a key technology for producing complex automotive components. However, the high cost and limited availability of primary aluminum powder restrict its large-scale application. This paper reviews the research progress and applications of recycled aluminum powder in 3D printing of automotive components. It systematically summarizes its sources, preparation processes, and particle properties, and further analyzes its applicability in additive manufacturing processes such as Selective Laser Melting (SLM) and Directed Energy Deposition (DED). Additionally, comparisons are made between components fabricated from recycled powder and virgin powder regarding their mechanical properties, thermal performance, and corrosion resistance. Key challenges were identified, including impurity control, process stability, and quality inspection. The results demonstrate that proper powder recycling and processing enable recycled aluminum powder to replace virgin powder in certain automotive components, thereby achieving cost reduction and enhanced material utilization efficiency while offering a potential solution for sustainable automotive manufacturing.