Additive Manufacturing (AM) has evolved into a powerful tool for Remanufacturing, greatly enhancing the possibilities in the areas of sustainability. AM has been celebrated for its material efficiency in part production, but its upstream feedstock supply remained energy-intensive and somewhat wasteful. The high material losses and carbon emissions inherent in powder and wire production posed a critical barrier to truly sustainable manufacturing.

The aim of this study was to evaluate and compare feedstock regeneration strategies for metal Additive Manufacturing. The goal was to identify which method offered the best balance of material savings, energy reduction, and practical applicability. A mixed-methods approach had been applied. First, technical data from a collaborative project has been analyzed. Then, a structured expert survey was conducted. Finally, three strategies were compared: mechanical conversion of machining chips into powder, solid-state consolidation of machining swarf into wire, as well as laser-based powder recovery using the CYCLAM process.

Results showed that solid-state wire consolidation can achieve over ninety percent material yield, with metallurgical integrity preserved and energy input reduced. Powder reshaping can improve usable powder yield and lowered energy use, but quality variations has confined its use to nonstructural components. The laser-based method had produced high-purity powder with substantial recycled content and minimal thermal damage, although its early development stage.

In conclusion, solid-state wire regeneration has been identified as the most mature and ready-to-deploy solution of the performance-critical applications considered, particularly in aerospace repair. Powder reshaping offered a scalable option for bulk parts, while the laser-based process presented a promising long-term pathway for complex, multi-material scrap. Further industrial scaletrials and comprehensive life-cycle assessments are recommended to confirm these findings and guide implementation.