Continuum Powders reduces emissions up to 98.7% in nickel powder production
Independent life cycle assessment by Oregon State University quantifies carbon impact using the company's plasma arc atomization technology
An independent life-cycle assessment conducted by Oregon State University’s Industrial Sustainability Laboratory found that nickel powder produced from recycled feedstock can reduce global warming potential (GWP) by up to 98.7% compared to conventional virgin-material production.
The cradle-to-gate study evaluated three production scenarios for nickel powder used in additive manufacturing. The baseline model used conventional gas atomization with 100% virgin nickel, and subsequent scenarios incorporated reclaimed feedstock processed through Continuum Powders’ plasma arc atomization technology at its Houston facility.
When recycled nickel feedstock replaced virgin material, modeled GWP dropped by 58.8%—that figure rose to 98.7% when lower-carbon electricity and argon sourcing were added as extra sustainability measures.
The LCA identified argon and electricity as the dominant contributors to greenhouse gas emissions in recycled-material scenarios. This suggests that feedstock selection and utility sourcing are among the most actionable variables for reducing the carbon intensity of nickel powder production.
Nickel powder serves as a critical feedstock for high-performance components used in aerospace propulsion, energy infrastructure, oil and gas equipment, defense platforms, and high-temperature industrial applications. Manufacturers in these sectors are coming under mounting pressure to reduce emissions, strengthen domestic supply chains, and manage exposure to geopolitical supply risk.
The OSU findings go some way toward repositioning powder sourcing as a strategic decision for OEMs, service bureaus, and contract manufacturers. Reclaimed feedstock reduces dependence on newly mined raw materials. It also offers a clear way to reduce Scope 3 emissions without changing the standards for powder quality or how well the materials perform.
Continuum Powders produces high-performance nickel alloy powders—including grades 718, 625, and M247—using reclaimed feedstock through its Melt-to-Powder platform, which combines certified revert streams with advanced atomization and process controls at its Houston facility.
The company stated the LCA results are consistent with its internal production data.
