The European research project CHIPART has developed a method to directly process titanium scrap from the aviation industry into metal powder for additive manufacturing, bypassing the energy-intensive remelting step in the traditional route. The project is supported by the European Defence Agency. Life cycle analysis shows that CO₂ emissions can be reduced by 85% to 92% compared to conventional titanium powder produced from primary raw materials. The recycled powder has passed tests in both LPBF and DED processes, with adjusted parameters achieving a relative density of at least 98% in parts. The short process route of titanium scrap-to-atomization has been validated, allowing the remelting step to be circumvented, providing an industrial pathway for the recycling of titanium alloy powder. Value for powder buyers: ① Successful validation of direct scrap-to-powder conversion means recycled titanium powder offers dual advantages in cost and carbon footprint, which will disrupt the pricing system of the traditional sponge titanium–melting–atomization route; ② Domestic sources of titanium processing scrap are abundant, and similar domestic routes are worth pursuing; ③ Monitor the supply of recycled titanium powder grades and progress in aviation certification to assess the feasibility and quality consistency of alternative procurement.