Powder Metallurgy and Additive Manufacturing Laboratory Driving Innovation in Industry
The Powder Metallurgy and Additive Manufacturing Laboratory is playing a key role in advancing the development and of powder materials and additively manufactured components. Equipped with state-of-the-art facilities, the laboratory supports industry partners by improving processes, increasing efficiency, and accelerating the wider adoption of additive manufacturing technologies.
Here a few examples of projects that highlight how we are helping organisations tackle real-world additive manufacturing challenges through innovation, data, and collaboration.
Real-Time Insights with In-Line Powder Data Analysis
This project focused on the development of prototype in-line powder characterisation equipment. Working closely with industry clients, the team developed systems capable of generating real-time data during production.
This approach enables manufacturers to detect process issues before product tolerances are exceeded, significantly reducing costly rework. It also creates a digital record of the process following the powder throughout the production chain.
By minimising the need for traditional laboratory testing, the system streamlines process monitoring. Additionally, the data feeds into machine learning models, helping predict other powder properties and providing deeper insights into powder usage, reuse, and production planning.
Investigating Reuse and Recycling of Surplus Metal Powders
Metal powder users currently face high disposal costs for used and waste powder material. This project sought to explore sustainable alternatives to disposal.
We looked at the barriers preventing this powder from being melted and re-atomised into new feedstocks, including industry standards and regulations and technical challenges. This involved developing software and Machine Learning (ML) tools, as well as screening powders, to see whether they could be re-directed for re-certification rather than re-melting.
The objective is to maximise material reuse, reduce waste, and support more sustainable manufacturing practices across the sector.
Powders for Fusion Reactor Component Development
In collaboration with industry partners, this project aimed to optimise Additive Manufacturing (AM) processing parameters of a new powder material for a prototype of a difficult-to-manufacture fusion reactor component - an area known for its demanding material and design requirements.
This required an Adaptive Design of Experiments approach, with feedback between Machine Learning (ML) model building and experiments. In addition, we looked at how this research could feed into material qualification and standards.
Adaptive design of experiments alongside machine learning accelerated the optimisation process while also contributing valuable insights toward future material qualification and industry standards.
Data-Driven Improvements in Powder Characterisation
Another key initiative focused on improving how metal powders are analysed and understood through enhanced data management.
The research team in the laboratory has developed a comprehensive database of historical characterisation data, alongside a robust sample tracking and data capture system. This allows new measurements to be contextualised quickly, helping identify issues more efficiently and reducing both time and cost.
The system also streamlines reporting and enables data to be adapted for real-world applications; it supports machine learning models that can identify the root causes of problematic powder behaviours, such as poor flowability.
As the database continues to grow, it is becoming an increasingly valuable resource for building understanding of powder properties and performance.
These projects are just a few examples of how, the Powder Metallurgy and Additive Manufacturing Laboratory is demonstrating how innovation, collaboration, and data-driven approaches can transform manufacturing processes—supporting industry in becoming more efficient, sustainable, and future-ready.
30 March 2026
