Over the last decade, laser powder bed fusion (LPBF) received increased attention as a method of producing complex-shaped products from various materials. Recent results indicate the potential of this technology for the production of intermetallic NiTi alloys with shape memory. Several studies have demonstrated a strong influence of the LPBF process conditions on the resulting material properties, i.e., the martensitic phase transformation temperatures, reversible/irreversible strain after cyclic loading, phase composition, chemical composition, etc. However, the mechanisms of functional properties altering during LPBF consolidation remain unexplored in the present state-of-the-art. This study aims to advance the knowledge about tailoring material properties of NiTi under laser influence. In this work, thin-walled samples were manufactured from pre-alloyed NiTi powder via LPBF in a wide window of laser power and scanning speed, excluding hatch spacing by employing a single track-based scanning strategy to reveal the pure effect of the laser’s influence. NiTi samples were characterized by various methods such as differential scanning calorimetry, X-ray diffraction, and mechanical tests. Established relationships between NiTi properties and the LPBF process conditions provide the basis for the development of NiTi production protocols with controlled functional properties.

Sustainable feedstock management remains a major challenge in laser beam powder bed fusion (PBF-LB), where conventional reuse strategies are typically limited to sieving and blending rather than full material regeneration. Ultrasonic atomization (UA) offers a fundamentally different powder production route based on capillary-wave instabilities induced at the surface of a molten metal by high-frequency vibrations. In contrast to turbulence-driven atomization, droplet formation in UA is primarily governed by ultrasonic frequency and intrinsic thermophysical properties of the melt, enabling quasi-deterministic particle formation with high sphericity and reduced satellite formation. In this study, ultrasonic atomization was investigated as a closed-loop route for converting PBF-LB-manufactured 316L stainless steel parts into reusable powder. Printed rods were remelted and atomized under controlled variation of electric current and vibration amplitude. The resulting powders were characterized in terms of morphology, internal microstructure, particle size distribution, chemical composition, and gas impurity content. UA produced highly spherical particles with reduced internal porosity and improved flowability compared to the initial gas-atomized powder, while preserving the principal alloying elements. An increase in oxygen content was observed after recycling, attributed to selective high-temperature oxidation under residual oxygen in nominally inert conditions. The results establish a mechanistic framework for transforming consolidated PBF-LB material into secondary feedstock and identify key parameters governing structural and compositional stability in closed-loop recycling.