Comparative evaluation of powder spreading strategies to enhance powder bed quality in powder bed fusion additive manufacturing: A DEM simulation study

作者：Seungkyun Yim, Hao Wang, Kenta Aoyagi, Yamanaka Kenta, Akihiko Chiba · 发表于：Powder Technology · 年份：2025 · DOI：10.1016/j.powtec.2025.120614 · 被引用次数：11 · 研究领域：Additive Manufacturing Materials and Processes、Additive Manufacturing and 3D Printing Technologies、Particle Dynamics in Fluid Flows

In this study, we proposed alternative spreading techniques aimed at enhancing the powder bed properties in powder bed fusion additive manufacturing, utilizing discrete element simulations. Our findings revealed significant alterations in the powder spreading regime depending on the adopted spreading strategies. In powder spreading with two blades, the climbing regime in the powder pile was eliminated due to the high compressive condition. The powder spreading with two blades can enhance the homogeneity of the powder bed by maintaining a steady powder pile throughout the spreading process. The spreading with the funnel resulted in superior packing density and reduced surface roughness by effectively mitigating surface pores and loosely packed regions. The force arch formation in spreading with the funnel was suppressed throughout the spreading process, facilitated by rapid kinetic energy dissipation within the downsized powder pile. The high cohesive force of powders reduces packing density during the conventional spreading process, promoting the formation of surface pores. In spreading with the funnel, the influence of cohesive force on force arch formation and packing density was alleviated. Compared to conventional spreading techniques, spreading with the funnel improved both packing density and homogeneity of the powder bed under various gravity magnitudes. Therefore, it was demonstrated that the powder bed quality can be improved by employing the powder spreading with fu...