The use of cold spray additive manufacturing (CSAM) for large format component manufacture relies on powder suitability and the heat treatment post-processing to achieve the required properties.This study assessed the impact on performance of incorporating recycled non-deposited powder into virgin powder. A benchmark study was conducted, where the mechanical properties of samples produced by CASM using virgin and recycled feedstocks were compared.Recycled powder was tested for suitability for CSAM. Virgin powder was mixed with various proportions of recycled powder and used to manufacture test samples that were subsequently heat treated and mechanical tested, with performance compared against the 100% virgin material benchmark.Initial results showed that morphology of the recycled powder has a large impact on the volume that can be introduced.