With the increasing popularity of metal additive manufacturing, in particular the powder bed fusion (PBF) process for the production of end-use components in a wide range of industries, the ability to recycle un-melted powder increases the attraction of PBF. Previous research has characterised the effects of recycling the powder on both the powder characteristics and the resulting part properties. This research investigates the process of adding virgin, unused powder to this recycled material, namely powder rejuvenation. The effect of this rejuvenation process on the powder characteristics and the resulting part properties are monitored. As the rejuvenated powder is reused, the bulk powder characteristics and final part properties deteriorate. The research characterises the impact of this powder rejuvenation process on the powder characteristics and therefore, the resulting parts, allowing for long term utilisation of the costly powder material.