New approaches towards production of polymer powders for selective laser beam melting of polymers

Schmidt, Jochen; Sachs, Marius; Fanselow, Stephanie; Wirth, Karl‐Ernst; Peukert, Wolfgang

doi:10.1063/1.5016797

Cited by 5 publications

(6 citation statements)

References 17 publications

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“…The specimen produced from the dry particle coated composite material showed a lower surface roughness than specimen produced from non-coated, rounded material. An improvement of AM processability upon dry coating was also found for melt-emulsified, narrowly-distributed spherical PP powders (Fanselow et al, 2016;Schmidt et al, 2017), i.e. even for ideally shaped particle systems dry coating improves AM Frontiers in Chemical Engineering frontiersin.org processability.…”

Section: Figurementioning

confidence: 71%

“…All these interconnected effects along the whole process chain influence the final mechanical and functional properties of the produced parts (Kleijnen et al, 2019). The effect of particle shape and surface functionalization on particle interactions, powder spreadability and quality of L-PBFproduced specimen were investigated by Schmidt et al for a process chain consisting of (wet) comminution of polymers (Schmidt et al, 2012), thermal rounding in a heated downer reactor (Sachs et al, 2017;Gómez Bonilla et al, 2021b) and dry particle coating in a tumbling mixer for polystyrene (PS) (Schmidt et al, 2014;Schmidt et al, 2015), polybutylene terephthalate (PBT) (Schmidt et al, 2016a;Schmidt et al, 2016b;Schmidt et al, 2016c) and composite powder systems (filled systems, e.g. PBT-glass, PBT-Al 2 O 3 and blends, e.g.…”

Section: Figurementioning

confidence: 99%

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Dry powder coating in additive manufacturing

Schmidt

Peukert

2022

Front. Chem. Eng.

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Dry powder coating is used in many industries to tailor the bulk solid characteristics of cohesive powders. Within this paper, the state of the art of dry coating of feedstock materials for powder based additive manufacturing (AM) processes will be reviewed. The focus is on feedstock materials for powder bed fusion AM processes, such as powder bed fusion of polymers with a laser beam and powder bed fusion of metals with lasers or an electron beam. Powders of several microns to several ten microns in size are used and the feedstock’s bulk solid properties, especially the flowability and packing density are of immanent importance in different process steps in particular for powder dosing and spreading of powder layers onto the building area. All these properties can be tuned by dry particle coating. Moreover, possibilities to improve AM processability and to manipulate the resulting microstructure (c.f. grain refinement, dispersion strengthening) by adhering nanoparticles on the powders will be discussed. The effect of dry coating on the obtained powder properties along the whole AM process chain and the resulting part properties is assessed. Moreover, appropriate characterization methods for bulk solid properties of dry-coated AM powders are critically discussed.

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Section: Figurementioning

confidence: 71%

Section: Figurementioning

confidence: 99%

Dry powder coating in additive manufacturing

Schmidt

Peukert

2022

Front. Chem. Eng.

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“…The mechanical properties are important to achieve the functional values of the fabricated part (Schmidt et al, 2016). If any part does not fulfil functional requirements of the application, it means that it may not fetch value to the customer (Mukhopadhyaya, 2013 andDefense department, USA, 2011).…”

Section: Mechanical Properties Comparison Of Cast Parts With Sls Process Made Partsmentioning

confidence: 99%

Assessment of mechanical properties and flammability of magnesium oxide/PA12 composite material for SLS process

Tiwari

Pande

Bobade

et al. 2019

RPJ

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Purpose The purpose of this paper is to propose and develop PA2200-based composite powder containing 0-15 Wt.% magnesium oxide before directly using it in selective laser sintering (SLS) machine to produce end-use products for low-volume production in the engineering applications with keen focus to meet the functional requirements which rely on material properties. Design/methodology/approach The methodology reported emphasises PA2200-based composite powder containing 0-15 Wt.% magnesium oxide development for SLS process which starts with preparation and characterisation of composite material, thermal and rheological study of composite material to decide optimum process parameters for SLS process machine to get optimal part properties. Further, to verify composite material properties, a conventional casting methodology is used. The composition of composite materials those possessing good properties are further selected for processing in SLS process under optimal processing parameters. Findings The process parameters of SLS machine are material-dependent. The effect of temperature in X-ray diffraction profile is negligible in the case of magnesium oxide reinforced PA2200 composite material. The cyclic heating of material increases melting point temperature, this grounds to modify part bed temperature of material every time before processing on SLS machine to uphold build part properties, as well as material. With the rise in temperature, the Melt flow index and rheological property of materials change. The magnesium oxide reinforced PA2200 composite material has high thermal stability than pure PA2200 material. By the addition of small quantity of magnesium oxide, most of the mechanical property and flammability property improves while elongation at break (percentage) decreases significantly. Practical implications The proposed PA2200-based composite powder containing 0-15 Wt.% magnesium oxide material development system and casting metrology to verify developed material properties will be very useful to develop new composite material for SLS process with use of less material. The developed methodology has proven, especially in the case where non-experts or student need to develop composite material for SLS process according to the property requirement of applications. Originality/value Unlike earlier composite material development methodology, the projected methodology of polymer-based composite material and confirmation of material properties instead of commencing SLS process provides straight forward means for SLS process composite materials development with less use of the material and period of time.

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“…To address the problem of irregular particle shape, a post-processing method involving particle rounding can be employed to produce spherical polymer powders with good flow. [47][48][49] The ground powder particles are fed into a downer reactor where the dispersed particles are melted and rounded due to the effect of surface tension and subsequently solidify to produce spherical powder particles [50]. This postprocessing method is versatile and scalable; more importantly, it can be applied to any polymer that may be ground and melted without degradation, i.e., most thermoplastics and thermoplastic blends such as PS and PBT/PC [51,52].…”

Section: Pure Polymer Powdersmentioning

confidence: 99%

“…For instance, PP microspheres can be prepared via the dissolutionprecipitation process using xylene [18], during which the PP concentration and quenching temperature can be adjusted to optimize the size and morphology of the spherical powder particles that are produced. When the dissolution-precipitation process is coupled with dry-coating, the powder flow can be further improved and be comparable to that of a commercially available PA12 powder [49]. Polyolefin powders can alternatively be produced by melt emulsification [66].…”

Section: Commodity Polymersmentioning

confidence: 99%

Development and optimization of polypropylene-based powders for selective laser sintering

Tan¹

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This thesis contains material from 3 papers published in the following peerreviewed journals in which I am listed as an author.Chapter 2 is published as a section of L.J. Tan, W. Zhu, and K. Zhou. Recent progress on polymer materials for additive manufacturing, Advanced Functional Materials, 2020. p. 2003062. The contributions of the co-authors are as follows:• I reviewed the literature and drafted the manuscript.

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New approaches towards production of polymer powders for selective laser beam melting of polymers

Cited by 5 publications

References 17 publications

Dry powder coating in additive manufacturing

Dry powder coating in additive manufacturing

Assessment of mechanical properties and flammability of magnesium oxide/PA12 composite material for SLS process

Development and optimization of polypropylene-based powders for selective laser sintering

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