Italian additive manufacturing company Valland, as part of the ToZero project, has successfully converted aluminum alloy scrap from automotive body-in-white production into feedstock powder for laser powder bed fusion (LPBF) metal 3D printing. The project, funded under Italy's 'Innovation Agreement' program, brings together Valland, the Polytechnic University of Turin, the Polytechnic University of Bari, and the Fontana Group. Valland developed LPBF process parameters for recycled AA5083 aluminum alloy powder and printed a structural validation part, 'Voletto'—a car body structure connecting node. The recycled alloy exhibited no hot cracking during printing, and its mechanical properties and ductility met predefined targets; topology optimization reduced the part's mass from 1.68 kg to 0.8 kg. A life cycle analysis conducted in accordance with ISO 14040/44 standards showed that process optimization led to approximately a 73% reduction in carbon footprint. The project also identified key bottlenecks: the printing speed of recycled AA5083 remains significantly slower than that of commercial AlSi10Mg, and the trade-off between material quality and production efficiency is a core challenge that must be addressed before industrialization.