Closed-loop Additive Manufacturing of Lightweight Boron-alloyed Lattice Structures from High-tech Scrap: A Sustainable Path to Circular Metallurgy

This project aims to establish a closed-loop value chain for the production of lightweight lattice structures made from boron-alloyed high-strength steels. Utilizing advanced additive manufacturing technologies—Selective Laser Melting (SLM) and Plasma Arc Direct Metal Deposition (PAD)—the project focuses on processing high-tech industrial scrap sourced from end-of-life components in the aerospace, energy, and defence sectors.

The core innovation lies in integrating the recycling of boron-containing steels with additive manufacturing to create high-performance, application-specific lattice structures. These structures are optimized for use in extreme environments where properties such as energy absorption, heat resistance, and structural integrity are critical.

The process chain encompasses several key stages:

• Recycling and recovery of valuable alloying elements from complex scrap;

• Production of metal powders via inert gas atomization;

• Digital design optimization using digital twins and topology optimization;

• Fabrication of final parts via AM technologies (SLM & PAD).

By closing the material loop and valorizing high-value scrap, the project enhances sustainability, reduces CO₂ emissions, and supports the transition to a circular economy in advanced manufacturing sectors.