Copper is a critical material for energy transition and green technologies, making its sustainable use increasingly important. Its superior thermal and electrical conductivity make it highly well-suited for additive manufacturing (AM). In this study, copper sourced from offshore electrical cables was upcycled to produce high-quality metal powder for AM. The scrap was processed to separate the metal from plastic and rubber, then refined through ultrasonic atomization, achieving a purity of ~99.5% wt.% with minimal impurities. Characterization demonstrated good flowability, apparent and tap densities, and a well-distributed particle size. To assess its performance in AM, the powder was printed using Directed Energy Deposition (DED) with a laser beam, confirming its high printability and compatibility with the base material. Finally, a comparative Life Cycle Assessment (LCA) revealed a significant environmental advantage of the recycling-based process over conventional mining, reducing global warming potential by more than 70%. These findings highlight the importance of feedstock origin in AM sustainability and support the adoption of circular economy strategies to lower the environmental footprint of advanced manufacturing.

This study compares five Si–Me infiltration coatings, Si:Mo (1:4), Si:Ti (1:1), Si:Zr (1:5), Si:Ta (1:1), and Si:W (1:5), deposited on C/C sonotrodes for ultrasonic atomization of CuSn8. The coatings were evaluated in terms of phase constitution, microstructure, wettability, nanoindentation response, and powder-production performance. XRD showed that the coatings formed distinct multiphase reaction layers, with Si:Ta (1:1) being the most silicide-dominated system, while the other coatings contained carbide or silicide–carbide phases. Metallization strongly improved the surface wettability of C/C, especially for Si:Zr (1:5) and Si:W (1:5). Nanoindentation indicated the most favorable H/E* and H³/E*² descriptors for Si:W (1:5) and Si:Mo (1:4). All coatings enabled high powder yields in single-run atomization tests, while apparent differences in particle-size distribution were observed among the coating conditions. Overall, the results show that coating selection for ultrasonic atomization should combine phase constitution, surface-state descriptors, near-surface mechanical response, layer retention, and process performance. Within the investigated conditions and the limitation of single-run atomization experiments, Si:W (1:5) emerged as the most promising and best-balanced coating candidate, while Si:Ta (1:1) and Si:Mo (1:4) remained relevant alternatives.