Virgin Powder Research Articles

The Mechanical Properties of Aged PA-12 FS3300PA Powder: Influence of Layer Thickness, Sintering Orientations, and Laser Power

Abstract This research investigates the influence of layer thickness, laser power, and sintering orientation on the mechanical properties of aged Polyamide-12 (PA-12) FS3300PA using the Selective Laser Sintering (SLS) 3D printing method. Specimens were sintered with three different layer thicknesses, laser powers, and sintering orientations using SLS. The study also aimed to examine the resulting powder morphology, mechanical properties, and tensile fracture behaviors of the aged (more than eight continuously sintering cycles) and virgin FS3300PA powders. The specimens divided into ten groups: nine groups of aged powder and one group of virgin powder as a benchmark. The nine groups of aged powder were sintered with three different layer thicknesses (0.07 mm, 0.12 mm, and 0.15 mm), laser powers (65W, 70W, and 75W), and orientations (YZY 0⁰, YZY 90⁰, and XYY 0⁰). The selections of these laser power and layer thickness values for the sintering setting are due to machine and material parameter limitation. The results from these parameters then compared with those of the virgin powder, which sintered using the parameters provided by the manufacturer, in terms of powder morphology, mechanical properties, and tensile fracture behaviours. Observation made using scanning electron microscope (SEM) revealed that there were not many changes in shape, size, and distribution between the virgin and aged powder, but slightly larger sizes and the presence of cracks found in the aged powder. The tensile strength, elongation at break value, and Young’s modulus all shared a similar trend, increasing with higher laser power but decreasing with increased layer thickness. Regarding the fracture morphologies, the number of pores and dimples decreased with increased laser power but increased with thicker layer thickness. There was also the occurrence of un-molten powder, especially in specimens sintered at the YZY 90⁰ orientation with lower laser power and thicker layer thickness.

Lithium extraction from geothermal brine using γ-MnO2: A case study for Tuzla geothermal power plant

Geothermal brines contain high concentrations of ions and form a source of various valuable elements. The isolation of the elements from their water systems is a great challenge when the gradual depletion of ores in mining is considered. Attempts have been made for a long time to isolate valuable elements from aqueous mixtures prepared in the laboratory. However, those studies might not reflect the complexity of natural systems and might yield results that deviate significantly from the performance in real field systems. In this study, sorption is used to extract lithium ions from a representative field, Tuzla Geothermal Power Plant (TGPP) Turkey, using a mini-pilot reactor introduced to the reinjection well of the plant. Electrolytic manganese dioxide (γ-MnO2), a relatively inexpensive material widely used as the cathode material in lithium-ion batteries, was employed as a sorbent material for lithium. The sorption/desorption performance of the novel γ-MnO2 was investigated under various conditions. Sorption is performed at 360K and 2 bars. The maximum sorption performance was obtained at 1 h in Tuzla GPP. The desorption experiments were performed in acidic solutions. The concentration of Li+ in the desorption solution was found to be 25 mg/L on average when 10 g of γ-MnO2 was dispersed into 30 mL of the acidic aqueous solution. The first desorption solution was used consecutively for collecting more Li+ ions through the desorption of fresh brine-treated powder samples (cumulative desorption). By repeating this process four times consecutively, 230 mg/L of Li+ was obtained in the desorption solution. Moreover, the reusability of the γ-MnO2 sorbent was examined. The sorbent powder showed almost 40% performance efficiency compared to virgin powder under the conditions employed in this study. The use of electrolytic γ-MnO2 sorbent for lithium adsorption was found to be a promising process for practical use in the separation of lithium from geothermal brines.

Effect of Powder Reuse on Powder Characteristics and Properties of DED Laser Beam Metal Additive Manufacturing Process with Stellite® 21 and UNS S32750

In this work, the influence of powder reuse up to three times on directed energy deposition (DED) with laser processing has been studied. The work was carried out on two different gas atomized powders: a cobalt-based alloy type Stellite® 21, and a super duplex stainless steel type UNS S32750. One of the main findings is the influence of oxygen content of the reused powder particles on the final quality and densification of the deposited material and the powder catch efficiency of the laser deposition process. There is a direct relationship between a higher surface oxidation of the particles and the presence of oxygen content in the particles and in the as-built materials, as well as oxides, balance of phases (in the case of the super duplex alloy), pores and defects at the micro level in the laser-deposited material, as well as a decrease in the amount of material that actually melts, reducing powder catch efficiency (more than 12% in the worst case scenario) and the initial bead geometry (height and width) that was obtained for the same process parameters when the virgin powder was used (without oxidation and with original morphology of the powder particles). This causes some melting faults, oxides and formation of undesired oxide compounds in the microstructure, and un-balance of phases particularly in the super duplex stainless steel material, reducing the amount of ferrite from 50.1% to 37.4%, affecting in turn material soundness and its mechanical properties, particularly the hardness. However, the Stellite® 21 alloy type can be reused up to three times, while the super duplex can be reused only once without any major influence of the particles’ surface oxidation on the deposited material quality and hardness.

In-situ monitoring of sintering and analytical modeling of densification and shrinkage in binder jetted 316 L stainless steel

In binder jetting, shrinkage and deformation occur during the sintering step, both of which are affected by the green density of the binder jetted materials. The study innovatively introduces a cost-effective, practical, and in-process monitoring system for visualizing shrinkage and deformation on larger samples than conventionally observed using small-scale specimens in dillatometry equipment. The powder characteristics and binder jet printing process itself influence the initial green density. The comprehensive analysis of powder flowability and packing density, densification behavior, and shrinkage reveals that the consolidated parts using virgin powder (with a green density of 55 %) can achieve a relative density above 99.9 % with an anisotropic shrinkage in the Z > X > Y direction. In contrast, the used or recycled powder exhibits a lower green density of ∼48 %, higher shrinkage rate in all three dimensions, and a decreased degree of anisotropy. Using in-process imaging and experimental data on the grain size attained through optical microscopy and electron backscatered diffraction imaging, the material's shear and bulk viscosities were determined. The formation of delta-ferrite and its impact on densification were discussed in the context of solid-state and supersolidus liquid phase sintering. The model relied on the continuum sintering theory formulated by Skorohod and Olevsky. The strain evolution from the in-situ imaging of sintering process is correlated with porosity based on the used feedstock and applied sintering temperatures. The outcomes of this study offer valuable perspectives on anisotropic sintering mechanisms, bridging the knowledge gap regarding the relationships between structures produced through binder jetting and subsequent sintering of materials.

On the potential of eddy current characterization of the ferritic content of recovered 316L powders after LaserPowder bed fusion fabrication

An original container was designed to measure the ferritic content of powder batches by the Eddy Current (EC) technique. As opposed to the standard X-Ray Diffraction (XRD) or Electronic BackScatter Diffraction (EBSD) methods, the EC measurements can be implemented on powder batches of significant sizes, say a hundred grams or so. Using a methodology based on the multiple recycling of an initially ferrite-free virgin powder, it was shown that the EC signals are sensitive to the ferritic content of the recovered powder. On the other hand, in the frequency range scanned by the sensor, the EC signals are virtually independent on the oxygen concentration within the tested powder.

Reuse of Smoulder in Laser Powder-Bed Fusion of AlSi10Mg—Powder Characterization and Sample Analysis

Metal additive manufacturing technologies, such as Laser Powder-Bed Fusion, often rate as sustainable due to their high material efficiency. However, there are several drawbacks that reduce the overall sustainability and offer potential for improvement. One such drawback is waste emerging from the process. These smoulder particles form when the laser hits the powder-bed surface, are blown away from the part by the shielding gas stream and accumulate on the edge of the build chamber. Usually, smoulder does not contribute to the circular reuse of powder that was part of the powder-bed but was not integrated into a part. Instead, it marks an end-of-life state of powder. Significant amounts of smoulder accumulate depending on the irradiated area or the build volume in one job, respectively. This results in the waste of powder that was produced with low energy efficiency. This study investigates the question of whether smoulder can transform from waste to resource via common powder characterization methods and first build jobs using processed smoulder. The investigation of process-relevant powder properties like apparent density and flowability showed no significant difference between virgin powder and smoulder. Sample characterization indicated that neither porosity, surface quality nor mechanical properties deteriorate when samples contain about 50% smoulder. This allows for the reuse of smoulder in terms of powder characterization and part quality.

Comparative Evaluation of Titanium Feedstock Powder Derived from Recycled Battlefield Scrap vs. Virgin Powder for Cold Spray Processing.

Gas-atomization is extensively used to produce metallic feedstock powders for additive manufacturing processes, including gas dynamic cold spray processing. This work explores the potential utility of on-demand recycled titanium scrap feedstock powder as a viable substitute for virgin powder sources. Three recycled titanium powders were atomized from different battlefield scrap sources using a mobile foundry developed by MolyWorks Materials Corporation. Recycled titanium alloy powders were compared against virgin Ti-6Al-4V powder to verify there were no significant variations between the recycled and virgin materials. Powder characterization methods included chemical analysis, particle size distribution analysis, scanning electron microscopy (SEM), Karl Fischer (KF) titration moisture content analysis, X-ray diffraction (XRD) phase analysis, microparticle compression testing (MCT), and nanoindentation. Results indicate that recycled titanium powder provides a viable alternative to virgin titanium alloy powders without compromising mechanical capabilities, microstructural features, or ASTM-specified composition and impurity standards. The results of this work will be used to aid future research efforts that will focus on optimizing cold spray parameters to maximize coating density, mechanical strength, and hardness of recycled titanium feedstock powders. "Cold spray" presents opportunities to enhance the sustainability of titanium component production through the utilization of recycled feedstock powder, mitigating issues of long lead times and high waste associated with the use of conventional virgin feedstock.

The Effect of Powder Re-Use on the Coalescence Behaviour and Isothermal Crystallisation Kinetics of Polyamide 12 within Powder Bed Fusion.

Polymer powder bed fusion (PBF) is becoming increasingly popular for the fabrication of lightweight, high-performance parts, particularly for medical and aerospace applications. This study investigates the effect of powder re-use and material aging on the coalescence behaviour, melt flowability, and isothermal crystallisation kinetics of polyamide-12 (PA-12) powder. With increased powder re-use, a progressive reduction in melt flowability and material coalescence is observed; at 200 °C, the particle consolidation time increases from 15 s in virgin powder to 180 s in powder recovered from build 6. The observed changes in the behaviour of PA-12 were attributed to polycondensation and cross-linking; these aging phenomena also create structural defects, which hinder the rate and extent of primary crystallisation. At an isothermal crystallisation temperature of 165 °C, the crystallisation half-time increased from 12.78 min in virgin powder to 23.95 min in powder re-used across six build cycles. As a result, the commonly used Avrami model was found to be unsuitable for modelling the crystallisation behaviour of aged PA-12 powder, with the co-efficient of determination (R2) reducing from >0.995 for virgin powder to as low as 0.795 for re-used powder. On the other hand, an alternative method, the Hay model, is able to successfully track full phase transformation within re-used powder (R2 > 0.99). These results highlight the importance of selecting the most appropriate model for analysing the crystallisation kinetics of PA-12 powder re-used across multiple build cycles. This understanding is crucial for obtaining the strong mechanical properties and dimensional precision required for the fabrication of functional, end-use parts within PBF.

Impact of Electron Beam Melting process recycling on defects and microstructure of Ti-6Al-4V powders

Metal powders are used as the feedstock material during the Electron Beam Melting processes. The process involves using an electron beam as the energy source to produce intricate parts with complex shapes in a layer-by-layer production system. The electron beam is directed by information from an STL file, and the process takes place in a pre-heated chamber that is maintained under vacuum. Once the production cycle is complete, the process yields the desired components along with a certain amount of residual powders that were not melted.To improve process efficiency and reduce costs associated with powder atomization, it is feasible to reuse the excess powder for subsequent production cycles. Prior to starting a new cycle, the excess powder is initially sieved to ensure a more uniform powder batch, and subsequently, the sieved powder can be mixed with other virgin powder to decrease oxygen content.This study examines the microstructure and defects present in a batch of virgin powders produced through plasma atomization and a batch of powders that were reused five times and mixed with Ti-6Al-4V grade 23 (ELI powders) at each cycle. The ELI powders are characterized by a low oxygen content.The results of the analysis indicate a connection between the powder atomization process and the formation of porosities in virgin powders resulting from trapped gas, as well as surface irregularities, including the presence of satellites. With an increase in the number of reuses, there is a reduction in the number of satellites, potentially due to surface partial melting due to the pre-heating of the EBM chamber, leading to rougher surfaces on the recycled particles.The microstructure of virgin powders is predominantly characterized by a fine acicular α’ phase, known as martensitic, formed due to the rapid cooling rate during the atomization process. Conversely, recycled powder tends to exhibit a coarser grain microstructure due to lower cooling rates. However, it is common to observe particles with a microstructure similar to that of newly manufactured powders, indicating that each individual particle has undergone a distinct thermal history.

Re-use of polyamide-12 in powder bed fusion and its effect on process-relevant powder characteristics and final part properties

Powder bed fusion (PBF) is an additive manufacturing technique capable of fabricating highly complex, individualised, and lightweight polymer components. However, to maximise the potential of PBF, in terms of both economic efficiency and environmental sustainability, a successful powder re-use strategy is essential. During a build, ageing and degradation processes affect the re-usability of un-sintered powder, so used powder is usually refreshed with virgin material before re-use. This study considers the effectiveness of using a 70:30 refresh ratio in a specific PBF technique: laser sintering (LS). Across a total of seven printing cycles, polyamide-12 (PA-12) powder refreshed with 30 % virgin material after each build, revealed a 4.5 °C increase in melting temperature. There was also a 20 % reduction in particle flowability, which may be related to the presence of fine satellite particles and considerable particle cracking. This deterioration in powder quality resulted in a 5.8 % increase in total part porosity, and an 11 % reduction in the ultimate tensile strength of fabricated parts, over the seven build cycles. A Pearson correlation test indicated that the reduction in powder flowability was the most significant (p-value of 0.005) cause for the loss of part strength; emphasising that the revolution powder analyser could be a useful complimentary technique for determining the quality of used powder within laser sintering. Nonetheless, compared to previous studies which re-used 100 % aged PA-12 powder, without refreshing with any virgin material, the observed reduction in part strength is relatively modest. This suggests that a 70:30 refresh ratio offers a good compromise between maintaining part performance, particularly for non-critical applications, without having to add an unnecessary amount of virgin powder. Therefore, this study reveals the relationship between the deterioration of powder properties and reductions in part strength; yet highlights the benefits of operating with a 70:30 refresh ratio when re-using PA-12 powder across multiple build cycles.

Mechanical properties characterization of Ti-6Al-4 V grade 5 (recycled) additively manufactured by selective electron beam melting (EB-PBF)

Additive manufacturing, a rapidly expanding technology, enables the production of intricate parts through the successive layering of materials. However, there remains a dearth of research on the viability of incorporating recycled powder into this process, with the potential to decrease expenses and enhance sustainability. This study's objective is to investigate the ramifications of employing recycled Titanium Ti-6Al-4 V alloy powder, for up to ten cycles, without the addition of virgin powder, in the context of additive manufacturing. The findings reveal that the mechanical properties of the material experience an approximate 40 % degradation in comparison to virgin powder. In ultrasonic very high-cycle fatigue tests (VHCF), the failure stress in the Z direction for additive manufacturing EB-PBF equals or surpasses 245 MPa. This research makes a significant contribution to the sustainable advancement of additive manufacturing, as it demonstrates the potential for recycling Titanium Ti-6Al-4 V grade 5 powder for the production of new items. This not only reduces costs but also serves the environment by circumventing unnecessary material disposal. Consequently, the outcomes of this investigation underscore the promising prospects of additive manufacturing with recycled powder, ushering in fresh opportunities for the industry, especially with regards to sustainability and environmental responsibility.

Effect of recycled powder and gear profile into the functionality of additive manufacturing polymer gears

PurposePolymer laser powder bed fusion (PBF-LB/P) is an additive manufacturing technology that is sustainable due to the possibility of recycling the powder multiple times and allowing the fabrication of gears without the aid of support structures and subsequent assembly. However, there are constraints in the process that negatively affect its adoption compared to other additive technologies such as material extrusion to produce gears. This study aims to demonstrate that it is possible to overcome the problems due to the physics of the process to produce accurate mechanism.Design/methodology/approachTechnological aspects such as orientation, wheel-shaft thicknesses and degree of powder recycling were examined. Furthermore, the evolving tooth profile was considered as a design parameter to provide a manufacturability map of gear-based mechanisms.FindingsResults show that there are some differences in the functioning of the gear depending on the type of powder used, 100% virgin or 50% virgin and 50% recycled for five cycles. The application of a groove on a gear produced with 100% virgin powder allows the mechanism to be easily unlocked regardless of the orientation and wheel-shaft thicknesses. The application of a specific evolutionary profile independent of the diameter of the reference circle on vertically oriented gears guarantees rotation continuity while preserving the functionality of the assembled mechanism.Originality/valueIn the literature, there are various studies on material aging and reuse in the PBF-LB/P process, mainly focused on the powder deterioration mechanism, powder fluidity, microstructure and mechanical properties of the parts and process parameters. This study, instead, was focused on the functioning of gears, which represent one of the applications in which this technology can have great success, by analyzing the two main effects that can compromise it: recycled powder and vertical orientation during construction.

Effect of Powder Bed Fusion Laser Sintering on Dimensional Accuracy and Tensile Properties of Reused Polyamide 11.

Polyamide 11 (PA11) is a plant-based nylon made from castor beans. Powder bed fusion laser sintering (PBF-LS) is an additive manufacturing process used for PA11 which allows for the reuse of the unsintered powder. The unsintered powder is mixed with virgin powders at different refresh rates, a process which has been studied extensively for most semi-crystalline polyamides. However, there is lack of information on the effect of using 100% reused PA11 powder and the effect of the number of times it is reused on its own, during powder bed fusion laser sintering. This paper investigates the effect of reusing PA11 powder in PBF-LS and the effect of the number of times it is reused on the dimensional accuracy, density and thermal and tensile properties. From the 100% virgin powder to the third reuse of the powder, there is a decrease in powder wastage, crystallinity and tensile strength. These are associated with the polymerisation and cross-linking process of polymer chains, upon exposure to high temperatures. This results in a higher molecular weight and, hence, a higher density. From the fourth reuse to the tenth reuse, the opposite is observed, which is associated with an increase in high-viscosity unmolten particles, resulting in defects in the PBF-LS parts.

Developing Four Powder Recycling Strategy for Sustainable Additive Manufacturing 3D Printing Process

This paper presents a detailed analysis of four different powder recycling strategies for the metal additive manufacturing process focused on examining the efficacy of recycling Ti6Al4V alloy powder for the Laser-Based Powder Bed Fusion (LBPF) process. The study evaluates four distinct recycling strategies (A, B, C, D) and their impact on powder-saving mechanisms. The experimental methodology involves careful leftover powder sampling, implementation of recycling strategies and print cycle analysis from each recycling strategy. The results show that Strategies C and D exhibit the lowest powder waste, allowing 6 times the reuse of leftover powder and producing 384 parts with minimal powder waste at the end of the process. Strategy B also performs well, enabling 8 cycles and building 512 parts with only a small amount of powder wasted. Conversely, Strategy A yields the highest powder waste despite achieving the same number of cycles and prints. This proposed approach requires a total volume of 224,000 mm3 of powder for each build. This entails using 500g of gas-atomized Ti-6Al-4V powder, with an average particle size D90 of approximately 50 μm. This features a continuous mixing technique, wherein each build combines 50% virgin powder with 50% of the previously collected and sieved powder.

Effective Ti-6Al-4V Powder Recycling in LPBF Additive Manufacturing Considering Powder History

Laser powder bed fusion (LPBF) is an outstanding additive manufacturing (AM) technology that can enable both complicated geometries and desired mechanical properties in high-value components. However, the process reliability and cost have been the obstacles to the extensive industrial adoptions of LPBF. This work aims to develop a powder recycling procedure to reduce production cost and minimize process uncertainties due to powder degradation. We used a recycle index (R) to reuse Ti-6Al-4V powder through 10 production cycles. Using this recycle index is more reasonable than simply replying on recycle numbers as it incorporates the powder usage history. A recycling procedure with simple virgin powder top-up can effectively mitigate powder degradation and maintain stable powder properties, chemical compositions, and tensile properties. The experimental finding points to a sustainable recycling strategy of Ti alloy powders with minimal material waste and without noticeable detriment to observed mechanical performance through LPBF production cycles.

A comprehensive characterization of the effect of spatter powder on IN939 parts fabricated by laser powder bed fusion

This study is focused on a comprehensive characterization of virgin and spatter IN939 powders and the effects of a certain amount of spatter powder on the part quality of IN939 fabricated by the L-PBF process. A brown tint coloration formed Al2O3 oxide, pores, a 124.4% increase in the average particle size, a 10.2% decrease in the powder circularity, and a 7.5% decrease in the powder aspect ratio were observed in the spatter powder. Additionally, higher average grain size and lower nanohardness were obtained for the spatter powder. In order to understand the effect of a certain amount of spatter powder on the part quality, 10 wt% spatter powder was mixed with the virgin powder. This addition was found to decrease the flowability of the powder. Moreover, this addition decreased relative density by around 0.3% and increased surface roughness by around 80.8% in the fabricated samples (termed as V and SV). On the other hand, there was no considerable microstructural, texture, microhardness, and nanohardness difference between V and SV samples, although the spatter powder addition caused a 30.2% increase in the average grain size of SV. The overall texture for both V and SV samples exhibit (001)//BD.

On the structural integrity and fatigue performance of additively manufactured Ti-6Al-4V parts processed using mechanically recycled powders

In light of the steadily increasing importance of resource efficiency, powder recycling represents one of the major prospects in additive manufacturing. The present study focuses on Ti6Al4V parts manufactured by electron beam-based powder bed fusion using blends of virgin and recycled powder. The latter powder was gained by mechanical comminution of support structures and, thus, addresses a novel topic beyond the well-known reuse of un-melted powder. Microstructure analysis is conducted by scanning electron microscopy and micro-computed tomography, mechanical properties are analyzed by quasi-static tensile and fatigue tests. Thereby, the applicability of recycled powder is assessed, eventually revealing that mechanically recycled powder can be qualified to partially substitute virgin powder in powder bed additive manufacturing.

Comparative analysis and characterization of used and unused Alsi10mg powders

Reducing waste through powder reuse is one way to overcome the economic barrier brought on by the high cost of metal additively produced components. As a result, this study aimed to thoroughly characterize four AlSi10Mg metal powders from two various manufacturers, used and unused, as well as sieved and un-sieved. Analysis of various parameters such as the static angle of repose (AOR), particle shape, particle size distribution, and the angle of internal friction (AIF) were calculated. Based on AOR and flowrate, it was found that the virgin powder from the first manufacturer has better flow characteristics and shape than the other powders. It was showed that Virgin powder, used sieved powder, and used un-sieved powder of manufacturer 2, have higher AIF values than the Virgin powder of manufacturer 1, implying that they can sustain lateral stresses better. According to the experiment, sieved, previously used powders can still be employed in additive manufacturing.

Maraging steel powder recycling effect on the tensile and fatigue behavior of parts produced through the laser powder bed fusion (L-PBF) process

Additive manufacturing (AM) has advanced the manufacturing industry and has been employed in a wide range of industrial applications, including aerospace, automotive, medical, and die-casting equipment. To ensure the cost-effectiveness of the AM process, unfused powder must be recycled even if its characteristics may change after each cycle, making essential the validation of powder quality and component mechanical performances. Despite the research published to date, predicting the mechanical performance of printed parts issued from reused powder remains challenging since it is dependent on many AM process variables. Until now, no research has looked at the impact of powder recycling on the fatigue behavior of maraging steel components. This study investigates the impact of maraging steel powder reuse on powder characteristics, as well as on the tensile and fatigue properties of printed components. Our results indicate that the powder particle size distribution increased after eight powder reuses, particle morphology showed the presence of aggregates, broken particles, and shattered and deformed particles, while powder apparent density remained constant. Powder reusing had no significant impact on the surface roughness of as-built specimens. Although there was a slight decrease in mechanical properties over reuse cycles, tensile and fatigue performance remained globally stable, while the standard deviation of fatigue stress became narrower after eight cycles. Finally, fractography revealed that the fatigue fracture surfaces of components manufactured from an eight-time recycled powder have more fusion defects and carbon inclusions than the parts made from virgin powder.

Validation of lumbar fusion device TILIF (Ti-6Al-4 V) manufactured by EBM additive manufacturing through fem modeling high cycle fatigue tests

This study aims to validate the computational fatigue analysis of a Transforaminal Lumbar Intervertebral Fusion (TLIF) prosthesis using high cycle fatigue (HCF) test data through the Finite Element Analysis Method (FEM). The Additive Manufacturing by Electron Beam Fusion process enables the construction of complex geometries for lumbar fusion prostheses, making it the preference of manufacturers for high-scale production. However, ensuring the structural validation of such products through static and dynamic tests can be time-consuming and expensive. Computational simulations using FEM can provide preventive and predictive analyses to anticipate structural problems arising from loads specified in projects, allowing for the development of geometric models that meet the mechanical tests requested by the ASTM F2077-18 standard. The HCF specimens were tested for fatigue life assessment between 107 cycles, improving test duration compared to traditional methods. The mechanical properties of the material, such as modulus of elasticity, yield strength, ultimate tensile strength, and density, were taken into account during testing. The results obtained through FEM were effective, demonstrating the predictive capability of this method in the development of new products manufactured by additive manufacturing technology using Titanium Grade 5. This research also compares the use of virgin powder and recycled powder in the manufacturing process, showing the differences in fatigue between the two materials. The study indicates that the mechanical properties of recycled powder are inferior to those of virgin powder, and as a result, the fatigue life of parts manufactured using recycled powder is lower than those manufactured with virgin powder. In conclusion, this study demonstrates the effectiveness of using computational fatigue analysis through FEM to predict the mechanical behavior of lumbar prostheses. The research provides valuable insights for manufacturers, indicating that the use of virgin powder in the manufacturing process can lead to longer fatigue life of the parts compared to the use of recycled powder.