journal article·2022-10

A literature review on powder spreading in additive manufacturing

Guanxiong Miao, Wenchao Du, Zhijian Pei, Chao Ma

Publisher page

Abstract

Powder-bed additive manufacturing, including powder bed fusion and binder jetting, has a wide range of applications in various industries. Powder spreading is a critical step of powder-bed additive manufacturing and has a determinative impact on powder bed quality and thus final part quality. This paper provides a literature review on powder spreading, focusing on the effects of influencing factors on powder bed quality. Three groups of influencing factors are discussed: spreaders, spreading parameters, and feedstock powder properties. Besides the effects of individual factors, the interaction effects between these factors are also discussed where applicable. Powder bed quality is discussed in terms of powder bed density and powder bed surface condition. Furthermore, knowledge gaps and research opportunities are presented as concluding remarks.
Source: expertdata · Quality: candidate unverified · Source record ↗

Research context

OpenAlex topics: Additive Manufacturing and 3D Printing Technologies · Additive Manufacturing Materials and Processes · Particle Dynamics in Fluid Flows

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

References (84)

Show source-provided references
1. Calculation of laser absorption by metal powders in additive manufacturing10.1364/AO.54.002477 ↗
2. Metal powder absorptivity: modeling and experiment10.1364/AO.55.006496 ↗
3. Fundamentals of energy conversion and dissipation in powder layers during laser micro sintering10.1016/j.phpro.2013.03.159 ↗
4. Analysis of scattering and absorption characteristics of metal powder layer for selective laser sintering10.1109/TMECH.2017.2705090 ↗
5. Numerical simulation in the absorption behavior of Ti6Al4V powder materials to laser energy during SLM10.1016/j.jmatprotec.2019.01.002 ↗
6. Effect of powder characteristics on parts fabricated via binder jetting process10.1108/RPJ-03-2018-0069 ↗
7. Physics-based model for equilibrium saturation determination in binder jetting additive manufacturing process10.1016/j.ijmachtools.2017.09.001 ↗
8. Contact thermal conductivity of a powder bed in selective laser sintering10.1016/S0017-9310(02)00370-8 ↗
9. Model of thermal conductivity in powder beds10.1103/PhysRevB.80.024202 ↗
10. An exploration of binder jetting of copper10.1108/RPJ-12-2014-0180 ↗
11. Binder jetting and infiltration of metal matrix nanocomposites10.1115/1.4053156 ↗
12. Metallurgical aspects of powder bed metal additive manufacturing10.1007/s10853-015-9479-x ↗
13. Laser additive manufacturing of metallic components: materials, processes and mechanisms10.1179/1743280411Y.0000000014 ↗
14. An overview of powder granulometry on feedstock and part performance in the selective laser melting
15. Review of selective laser melting: materials and applications10.1063/1.4935926 ↗
16. Additive manufacturing of metals10.1016/j.actamat.2016.07.019 ↗
17. Part and material properties in selective laser melting of metals
18. Binder jet 3D printing–process parameters, materials, properties, and challenges10.1016/j.pmatsci.2020.100707 ↗
19. Ceramic binder jetting additive manufacturing: a literature review on density10.1115/1.4046248 ↗
20. Metal binder jetting additive manufacturing: a literature review10.1115/1.4047430 ↗
21. Binder jetting: a review of process
22. The influence of printing parameters, post-processing, and testing conditions on the properties of binder jetting additive manufactured functional ceramics10.3390/ceramics3010008 ↗
23. Literature review: methods for achieving high powder bed densities in ceramic powder bed based additive manufacturing
24. S. Lee, Powder Layer Generation for Three Dimensional Printing, Master's thesis, Massachusetts Institute of Technology, 1992.
25. 3D printing of Al2O3/Cu–O interpenetrating phase composite10.1007/s10853-010-4896-3 ↗
26. Combining powder bed compaction and nanopowders to improve density in ceramic binder jetting additive manufacturing10.1016/j.ceramint.2021.09.077 ↗
27. The influence of powder apparent density on the density in direct laser-sintered metallic parts10.1016/j.ijmachtools.2006.03.019 ↗
28. On the measurement of relative powder-bed compaction density in powder-bed additive manufacturing processes10.1016/j.matdes.2018.06.030 ↗
29. Printability of calcium phosphate: calcium sulfate powders for the application of tissue engineered bone scaffolds using the 3D printing technique10.1016/j.msec.2014.01.027 ↗
30. Ceramic binder jetting additive manufacturing: effects of granulation on properties of feedstock powder and printed and sintered parts
31. Ceramic binder jetting additive manufacturing: relationships among powder properties, feed region density, and powder bed density10.1016/j.ceramint.2021.05.175 ↗
32. Effects of powder variation on the microstructure and tensile strength of Ti6Al4V parts fabricated by selective laser melting
33. New strategies for powder compaction in powder-based rapid prototyping techniques10.1016/j.procir.2013.03.100 ↗
34. Seluga · 2001
35. Binder-jet printing of fine stainless steel powder with varied final density10.1007/s11837-016-2177-6 ↗
36. Experimental and theoretical investigation on ultra-thin powder layering in three dimensional printing (3DP) by a novel double-smoothing mechanism10.1016/j.jmatprotec.2015.01.016 ↗
37. Fabrication of demineralized bone matrix/polycaprolactone composites using large area projection sintering (LAPS)
38. Influence of the ratio between the translation and contra-rotating coating mechanism on different laser sintering materials and their packing density
39. Effect of bimodal powder mixture on powder packing density and sintered density in binder jetting of metals
40. B. Liu, R. Wildman, C. Tuck, I. Ashcroft, R. Hague, Investigation the Effect of Particle Size Distribution on Processing Parameters Optimisation in Selective Laser Melting Process, Solid Freeform Fabrication Symposium, Austin, TX, US, 2011.
41. Measurement of powder bed density in powder bed fusion additive manufacturing processes10.1088/0957-0233/27/11/115601 ↗
42. Effect of powder compaction in plastic laser sintering fabrication
43. A method for measuring powder bed density in binder jet additive manufacturing process and the powder feedstock characteristics influencing the powder bed density
44. Mechanized spreading of ceramic powder layers for additive manufacturing characterized by transmission X-ray imaging: influence of powder feedstock and spreading parameters on powder layer density10.1016/j.powtec.2021.117053 ↗
45. Packing quality of powder layer during counter-rolling-type powder spreading process in additive manufacturing10.1016/j.ijmachtools.2020.103553 ↗
46. Powder-spreading mechanisms in powder-bed-based additive manufacturing: experiments and computational modeling10.1016/j.actamat.2019.08.030 ↗
47. Dynamic investigation on the powder spreading during selective laser melting additive manufacturing
48. Numerical simulation of particle flow and segregation during roller spreading process in additive manufacturing10.1016/j.powtec.2019.12.023 ↗
49. Critical influences of particle size and adhesion on the powder layer uniformity in metal additive manufacturing10.1016/j.jmatprotec.2018.10.037 ↗
50. Discrete element simulation and experimental study of powder spreading process in additive manufacturing10.1016/j.powtec.2016.11.002 ↗
51. Adhesion effects on spreading of metal powders in selective laser melting10.1016/j.powtec.2019.12.048 ↗
52. Effects of spreader geometry on powder spreading process in powder bed additive manufacturing10.1016/j.powtec.2021.02.022 ↗
53. The influence of material and process parameters on powder spreading in additive manufacturing10.1016/j.powtec.2021.01.058 ↗
54. Discrete element simulation of the effect of roller-spreading parameters on powder-bed density in additive manufacturing10.3390/ma13102285 ↗
55. Study of powder spreading in additive layer manufacturing10.1007/s10035-019-0971-x ↗
56. Powder bed layer characteristics: the overseen first-order process input10.1007/s11661-016-3470-2 ↗
57. Modeling of effect of powder spreading on green body dimensional accuracy in additive manufacturing by binder jetting10.1016/j.powtec.2021.02.070 ↗
58. Dynamic simulation of powder packing structure for powder bed additive manufacturing10.1007/s00170-018-1697-3 ↗
59. Optimisation of blade type spreaders for powder bed preparation in additive manufacturing using DEM simulations10.1016/j.powtec.2017.08.011 ↗
60. Numerical model for granular assemblies10.1680/geot.1979.29.1.47 ↗
61. Influence of grain size and grain-size distribution on workability of granules with 3D printing10.1007/s00170-013-5210-8 ↗
62. Influence of powder deposition on powder bed and specimen properties10.3390/ma12020297 ↗
63. Dynamics of short fiber/polymer composite particles in paving process of additive manufacturing
64. Is high-speed powder spreading really unfavourable for the part quality of laser powder bed fusion additive manufacturing10.1016/j.actamat.2022.117901 ↗
65. Structural ceramic components by 3D printing
66. Binder jetting additive manufacturing: observations of compaction-induced powder bed surface defects10.1016/j.mfglet.2021.04.003 ↗
67. S.J. Gregorski, High Green Density Metal Parts by Vibrational Compaction of Dry Powder in the Three-Dimensional Printing Process, PhD thesis, Massachusetts Institute of Technology, 1996.
68. μ-SLS of metals: design of the powder spreader, powder bed actuators and optics for the system
69. Vibrated powders: structure, correlations, and dynamics10.1103/PhysRevA.45.3435 ↗
70. Particle-based simulation of powder application in additive manufacturing10.1016/j.powtec.2015.10.035 ↗
71. Model guided mixing of ceramic powders with graded particle sizes in binder jetting additive manufacturing
72. Development process for custom three-dimensional printing (3DP) material systems10.1115/1.4000713 ↗
73. Flow behavior of powder particles in layering process of selective laser melting: numerical modeling and experimental verification based on discrete element method10.1016/j.ijmachtools.2017.08.004 ↗
74. Attractive particle interaction forces and packing density of fine glass powders10.1038/srep06227 ↗
75. The packing of particles10.1111/j.1151-2916.1930.tb16222.x ↗
76. Linear packing density model of grain mixtures10.1016/0032-5910(86)80058-4 ↗
77. Treatment of ferrous melts for the improvement of the sphericity of water atomized powders10.1016/j.matdes.2016.12.059 ↗
78. Performances of three models in predicting packing densities and optimal mixing fractions of mixtures of micropowders with different sizes10.1016/j.powtec.2021.117095 ↗
79. Laser sintering of blended Al‐Si powders10.1108/13552541211212096 ↗
80. Binder jetting additive manufacturing: effect of particle size distribution on density10.1115/1.4050306 ↗
81. Optimization of powder layer density in selective laser sintering
82. Characterization of feedstock in the powder bed fusion process: sources of variation in particle size distribution and the factors that influence them
83. Packing in the spheres10.1126/science.1094581 ↗
84. Oriented structure of short fiber reinforced polymer composites processed by selective laser sintering: the role of powder-spreading process10.1016/j.ijmachtools.2021.103703 ↗