Since the beginning of metallic powder-based additive manufacturing, identifying the ‘end-of-life powder’ and powder scrapping has been challenging. Powder recycling has the potential to achieve financial feasibility by plugging gaps in the circular economy of the additive manufacturing process. Components that are additively manufactured with ‘used powders’ often exhibit inferior quality, which eventually renders the powders unsuitable in additive manufacturing. Existing standards of additive manufacturing do not provide explicit instructions on identifying end-of-life powders or reusing powders. This results in a wide range of powder that additive manufacturing users deem “unusable”. Powder disposal issues have been noted as a problem in additive manufacturing. Consequently, it is necessary to research strategies for extending the shelf life of powders and avoiding the disposal of unused powder. However, few investigative studies have been reported detailing the affects of reused powder on the manufactured component or assigning criteria for the end-of-life of metal powders. This research investigates the deterioration of AlSi10Mg powder, repercussions such as quality problems, the use of end-of-life powder, and the differences between the processing parameters of new and recycled powder. This study may be helpful, in general, for the users of additive manufacturing and specifically who would continue their investigation of powder recycling.