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. Funded by Italy’s “Innovation Agreements” program, the project 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 called “Voletto”—a car body structural joint. The recycled alloy showed no hot cracking during printing, and its mechanical properties and ductility met predefined targets. Topology optimization reduced the part’s weight from 1.68 kg to 0.8 kg. A life cycle analysis conducted in accordance with ISO 14040/44 standards revealed that the optimized process reduced the carbon footprint by approximately 73%. The project also identified key bottlenecks: the printing speed for recycled AA5083 is still significantly slower than that of commercial AlSi10Mg, highlighting that balancing material quality and production efficiency is a critical issue that must be resolved before industrialization.