Continuum unveils Direct Powder Feeder for immediate re-atomising of reclaimed powder
Continuum Powders, based in Houston, Texas, USA, has announced the deployment of its next-generation Direct Powder Feeder (DPF), which enables unused advanced manufacturing powder to be reclaimed and fed directly back into the powder production process.
By reintroducing non-yielded powder into the atomisation process, without the need for intermediate consolidation, this innovation significantly reduces waste, shortens processing times, and preserves the integrity of high-value materials. In traditional workflows, powder left over after AM builds, whether oversized, undersized, or otherwise non-yielding, often goes unused or must undergo additional processing before it can re-enter production. Continuum’s Direct Powder Feeder eliminates these extra steps, allowing reclaimed powder to be re-atomised immediately. This is particularly impactful for reactive materials like titanium, where quality, oxygen control, and efficient material utilisation are critical.
Rizk Ghafari, COO of Continuum Powders, stated, “This is a game changer — it’s a major milestone in powder production. By reclaiming material that would otherwise be lost and returning it to the feedstock stream without compromising quality, we’re improving efficiency, reducing costs, and setting a new benchmark for circular manufacturing in advanced metals.”
David Vega, Manufacturing Manager, and Paul Meese, Technical Fellow, shared in a joint statement, “From the start, our goal has been to engineer systems that cut waste and keep valuable material in circulation.”
“The Direct Powder Feeder advances that mission by simplifying how reclaimed powder is fed back into our process—helping customers meet production demands while maximising powder quality and sustainability,” they added.
Alongside dedicated powder consolidation, which enables Continuum to puck and toll powder for external atomisation, the Direct Powder Feeder represents a leap forward in reclaiming and reusing feedstock with greater speed and precision.
Continuum’s advancements in powder reuse and atomisation efficiency align with its mission to deliver certified, high-performance metal powder solutions for advanced manufacturing, intended to help customers improve part quality, enhance supply chain resiliency, and accelerate innovation through deep partnerships, technical excellence, and sustainable practices. These improvements also reflect the company’s commitment to establishing a circular supply chain that meets the rigorous standards of industries such as aerospace, energy, and industrial manufacturing.
www.continuumpowders.com
