Additive manufacturing (AM) has established itself as a revolutionary technology that makes it possible to create complex components directly from digital models. For industrial high-tech applications, reactive powder materials such as titanium and aluminum are commonly used, though their fine particle form can pose risks of fire and explosion. The key considerations and conditions for the production (atomization) and metallurgical processing of such powder materials using AM techniques are presented, taking into account both safe working environments and the preservation of high material quality. Additionally, aspects of sustainability are discussed, which are of great importance for the development of ecological material cycles. Best practice examples are presented as the part of work flows recommended for both research labs and production environments. Critical work steps are highlighted and rules to be taken into account are explained. In addition, current challenges and strategies with regard to sustainability are discussed.