<p>Additive manufacturing via laser powder bed fusion (LPBF) enables the production of parts with excellent mechanical properties, including those with complex geometries. However, industrial adoption faces challenges due to production cost and process reliability concerns. In LPBF, the properties of metal powder feedstock are critical for consistent performance, with reusability playing a key role in reducing cost but raising reliability concerns. This study is focused on a holistic powder reusability study aiming to understand the relationships between powder feedstock and the resulting build part properties. Two distinct AlSi10Mg powder feedstocks, with differences in morphology and particle size distribution, were independently processed over 15 consecutive build cycles using a top-off reuse method with powder reconditioning after each cycle. Powder properties were evaluated at different cycles using a variety of standardized and non-standardized characterization techniques, while the chemical composition and mechanical performance of build coupons were also analyzed. The findings indicate that powder degrades with reuse, regardless of its initial quality, impacting mechanical properties. However, the degradation rate is influenced by the initial feedstock quality, with spherical powder degrading at a slower rate than irregular powder, impacting the mechanical performance. Overall, powder degradation upon reuse primarily affected morphology, particle size distribution, sphericity, and oxide layer thickness. In contrast, moisture content, powder flow, and tribocharging behaviors were found to be more dependent on the specific characteristics of each powder feedstock. The findings of this study emphasize the critical role of initial powder quality in determining the rate of degradation and their implications for industrial reuse strategies.</p>