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<p>Developing efficient and low-cost circular materials processes that upcycle metallic waste is essential for creating resource efficient and sustainable components. In this study, two-step processing routes for upcycling waste copper cables into high-purity copper additive manufacturing powder have been developed. High-temperature thermal decomposition at 650&#xa0;°C was employed to eliminate surface oxides and reduce oxygen content in waste copper. This treatment lowered the oxygen level in pretreated granules to 210 wt ppm, compared with 253 wt ppm in the original material. The pretreated granulated copper was then gas atomized with subsequent fluidized bed reactor (FBR) processing for conversion into high-purity copper powder suitable for Laser Beam Powder Bed Fusion (PBF-LB). Powder processing resulted in an oxygen concentration of 40 wt ppm, though downstream handling activity elevated oxygen levels to 116 wt ppm for powder used in PBF-LB. Mechanical and electrical properties of parts formed by PBF-LB were evaluated. The effect of oxygen content on electrical and thermal conductivity, and tensile properties were assessed. Electrical conductivity and the tensile strength of the recycled copper were comparable to the counterpart made using virgin powder feedstock. However, the recycled copper showed a 6–7% decrease in thermal conductivity and a 10–11% decline in ductility compared to virgin powder feedstock, attributed to poor printability and elevated defect levels caused by agglomerated atomized particles.</p> Graphical Abstract <p></p>

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Efficient Upcycling of Copper Waste into High-Purity Additive Manufacturing Powder Feedstock

  • 期刊论文

  • 发表日期：

    2026年2月2日

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  • Yijun Liu,
  • Benjamin Karbaron,
  • Chris Dalton,
  • Kieran Bullivant,
  • Aneta Chrostek-Mroz,
  • Thomas Rehaag,
  • William Hopkins,
  • Ronak Patel,
  • Steven Hall

摘要

Developing efficient and low-cost circular materials processes that upcycle metallic waste is essential for creating resource efficient and sustainable components. In this study, two-step processing routes for upcycling waste copper cables into high-purity copper additive manufacturing powder have been developed. High-temperature thermal decomposition at 650 °C was employed to eliminate surface oxides and reduce oxygen content in waste copper. This treatment lowered the oxygen level in pretreated granules to 210 wt ppm, compared with 253 wt ppm in the original material. The pretreated granulated copper was then gas atomized with subsequent fluidized bed reactor (FBR) processing for conversion into high-purity copper powder suitable for Laser Beam Powder Bed Fusion (PBF-LB). Powder processing resulted in an oxygen concentration of 40 wt ppm, though downstream handling activity elevated oxygen levels to 116 wt ppm for powder used in PBF-LB. Mechanical and electrical properties of parts formed by PBF-LB were evaluated. The effect of oxygen content on electrical and thermal conductivity, and tensile properties were assessed. Electrical conductivity and the tensile strength of the recycled copper were comparable to the counterpart made using virgin powder feedstock. However, the recycled copper showed a 6–7% decrease in thermal conductivity and a 10–11% decline in ductility compared to virgin powder feedstock, attributed to poor printability and elevated defect levels caused by agglomerated atomized particles.

Graphical Abstract