On August 26, 2026, the international association IAMHH hosted a webinar titled "Metal Powder Upgrade, Reuse, and Engineering," presented by a co-founder of Ultra Metal Powders. The session explored three key engineering pathways: recovering and reclassifying oversize or agglomerated powders for reuse, modifying particle morphology to improve flowability and tap density, and applying surface functionalization to tune laser energy absorption. These approaches aim to reduce powder costs for LPBF and cold spray processes. Powder upgrade and reuse is a critical lever for lowering overall consumable costs in metal additive manufacturing and offers valuable insights for buyers developing circular usage strategies. As metal AM transitions from prototyping to serial production, full-lifecycle powder cost management has become a central theme for industrial cost reduction. Key takeaways for powder purchasers: (1) recovery and classification technologies can turn screened oversize powder into valuable feedstock, lowering total procurement costs; (2) surface functionalization opens a differentiated market for customized modified powders; and (3) procurement strategies should evaluate cost-optimized blends of virgin and reused powder.