EOS takes major step toward greener AM with 100% recycled AlSi10Mg
Taking the lead in a segment that has seen major initiatives unravel in polymer AM as well
The metal additive manufacturing (AM) industry is evolving rapidly, with a growing focus on sustainability. As global industries push for lower carbon footprints, more companies in the AM sector are implementing environmentally friendly production methods to create high-quality metal powders while reducing energy consumption and waste. One of the most significant advancements in this space now comes from EOS, which recently introduced its 100% recycled Aluminium AlSi10Mg. This innovation results in a 77% reduction in COâ‚‚e emissions compared to the previous version and an 83% reduction compared to virgin aluminum, demonstrating a major step toward greener AM materials.
EOS has positioned itself at the forefront of sustainable metal AM materials by ensuring that its fully recycled Aluminium AlSi10Mg maintains the same mechanical properties as its virgin counterpart. This means customers do not have to requalify applications, making it an easy and efficient transition to a more sustainable option. There is no price difference for the new material, and EOS Aluminum AlSi10Mg is available for purchase through the EOS Store or by contacting the EOS Life Cycle Solutions team.
EOS has also launched additional initiatives, such as the VIRTUCYCLE take-back program, which repurposes used polymer materials, and a Carbon Calculator, which helps businesses assess and reduce their AM-related emissions. These initiatives highlight EOS’s commitment to responsible manufacturing, reinforcing the industry’s shift towards reducing environmental impact without compromising material quality.
A move towards sustainable metal powders
EOS’s move to 100% recycled Aluminium AlSi10Mg is a significant milestone in sustainable additive manufacturing (AM), but it’s also part of a broader industry trend toward lowering carbon emissions, minimizing waste, and improving material efficiency.
Other companies are also leading sustainability efforts in metal AM. 6K Additive was among the first, by developing the UniMelt microwave plasma technology which transforms recycled materials into high-quality metal powders with nearly 100% yield in target particle sizes. This method repurposes scrap metal and end-of-life parts into reusable powder, reducing waste and improving efficiency. Continuum Powders has developed the Greyhound platform, a single-step process that converts alloyed metal waste into AM powders, achieving a 99.7% reduction in greenhouse gas emissions compared to traditional powder production. With its small-footprint atomization technology, Continuum POwders converts scrap metal into AM powders directly on-site, minimizing transportation emissions and material waste while supporting a decentralized production model. The startup f3nice also offers various metal AM powders from recycled feedstock (steel, nickel, titanium, copper).
Reducing carbon emissions in polymer AM
Beyond metal powders, several leading AM companies have made efforts to advance sustainability through different approaches. Materialise, via Bluesint PA 12, focuses on reusing 100% polymer powder in selective laser sintering, reducing material waste significantly. Stratasys has shifted towards biobased resins and energy-efficient 3D printing technologies, reducing reliance on fossil fuel-based materials. While these initiatives primarily focus on polymer and energy-efficient printing, they contribute to the overall sustainability movement within additive manufacturing.
EOS is now taking the lead in this area as well. The company offers a range of Responsible Products to reduce environmental impact in additive manufacturing. The VIRTUCYCLE® Used Polymer Material Take-Back Program repurposes used polymer materials and components, utilizing 100% sustainably sourced energy to transform AM powder into recycled high-performance injection molding granules.
In addition, PA 1101 ClimateNeutral polymer materials ensure 100% proven quality with zero COâ‚‚e emissions, as all remaining greenhouse gas emissions are offset through Gold Standard carbon credits. PA 2200 CarbonReduced polymer materials further minimize emissions through sustainable measures such as green energy use in production. Finally, the Carbon Calculator provides organizations with a detailed assessment of their AM-related COâ‚‚e emissions and associated costs, helping businesses make informed sustainability decisions.
