Why aerospace and defense manufacturers are embracing recycled powders—and how you can too
Modern aerospace engineering demands more from materials than ever before. Rising raw material costs, fragile supply chains, and increasing ESG requirements are putting pressure on manufacturers to rethink how they source and produce mission-critical parts.
Enter recycled metal powders—not just as a trend, but as a proven solution that’s already flying.
In our latest eBook we explore how certified recycled powders are helping manufacturers stabilize supply chains and dramatically cut carbon emissions—without compromising performance. And we explain exactly how Continuum Powders is leading this transformation.
A Cleaner, Smarter Path to Metal Powder
For years, recycled metal had a reputation problem in aerospace. It was seen as risky—unpredictable chemistry, poor flowability, inconsistent batches. That’s because not all recycled powders are created equal.
Our process is different.
At Continuum Powders, we start with certified aerospace-grade scrap metal—nickel, titanium, and high-performance superalloys—and transform it into new, high-quality powder through our proprietary Melt-to-Powder (M2P) process. Every batch is tested for chemistry, flow, particle shape, and traceability. The result? Powder that performs like virgin material but comes with a significantly smaller environmental and financial footprint.
What the Data Says
According to a Life Cycle Assessment (LCA) conducted earlier this year by Oregon State University, our powder production process generates just 117 kg of CO₂ per 100 kg of nickel-based powder—compared to 3,179 kg CO₂ using traditional virgin ore-based production. That’s a ~99.7% reduction in emissions.
For aerospace OEMs and Tier 1 suppliers focused on sustainability goals, that’s not just nice to have—it’s a critical differentiator.
Already in the Air
You don’t have to take our word for it. Industry leaders like Rolls-Royce and Boeing have long-standing closed-loop recycling programs. More than 95% of Rolls-Royce’s old parts and scrap are reused, and over 8 million pounds of aluminum scrap are recycled annually in the Boeing-Alcoa program.
Continuum’s approach builds on that legacy—delivering high-performance, sustainable powders for next-generation additive manufacturing and conventional applications alike.
The Continuum Advantage
- Certified Scrap Only: We only start with material that was already flight-approved.
- Clean, Controlled Processing: Every step, from melt to atomization, is tightly managed.
- Tested & Traceable: You get chemistry you can trust—and performance you can prove.
- S.-Based Sourcing: Fewer supply chain headaches and more domestic resilience.
Want to learn more?
Download the full eBook now and discover how your team can build a more sustainable, stable, and cost-effective metal powder strategy—without sacrificing quality.
Of course, if you have questions for our team, please don’t hesitate to reach out directly here.