Researchers from the Universities of Leeds and Greenwich and medical technology testing company Cormica Limited have published a comprehensive study on powder distribution in Powder Bed Fusion (PBF) 3D printing. The study, published in Particuology, sheds light on how the distribution of the powder affects the properties of the printed parts.
The scientists identify several key factors that influence powder distribution. These include particle size, shape, porosity and flow behaviour of the powder. The conditions during the printing process also play an important role. The distance between the distributor and the build plate, the speed of the distributor and ambient conditions all have an effect on the print quality.
According to the researchers, a key problem is the lack of standardised methods for evaluating powder distribution. Previous approaches based on conventional flowability measurements often show discrepancies with the actual behaviour of the powder in the printing process.
The study emphasises that individual powder properties are not sufficient to comprehensively characterise the spreadability. The authors argue in favour of a holistic approach that combines different measurement methods in order to better understand the complex interactions in the PBF process.
The study cites in-situ monitoring systems as a promising approach to process optimisation. These make it possible to adjust pressure settings in real time and thus increase reliability. The researchers emphasise that a deeper understanding of powder distribution is crucial in order to improve the quality and reproducibility of PBF 3D printing. They still see a considerable need for research in order to fully understand the relationships between powder properties, process parameters and component quality.
The complete study entitled “Spreadability of powders for additive manufacturing: A critical review of characterisation methods” can be accessed here.
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