DECOR creates a circular economy through a Danish scrap metal recycling ecosystem to make metal powders and ingots by spray-forming. Ingots made by spray-forming from high-alloy steels have a superior microstructure compared to cast material and provide superior tool performance. Overspray powder from the ingot manufacturing process has until now, generally been treated as an unwanted biproduct and recycled accordingly. Preliminary studies on the overspray powders have surprisingly demonstrated that the overspray powder consists of spherical particles with excellent flowability as required for Additive Manufacturing (AM). Converting scrap metal into high quality feedstock powders for AM alongside high quality ingots, constitutes an excellent sustainable business case for the spray-forming process. DECOR is a transformative solution for a circular economy of tailored alloy systems in the tooling industry by leveraging an agile manufacturing process to produce a predetermined ratio of ingots to powders, such that scrap from industry can be recycled into a sustainable process chain.