Processing parameters in laser powder bed fusion metal additive manufacturing

Oliveira, J.P.; LaLonde, Aaron D.; Ma, Ji

doi:10.1016/j.matdes.2020.108762

Cited by 571 publications

(173 citation statements)

References 74 publications

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“…Powder bed fusion (PBF) based 3D printing utilizes either a laser or an electron beam to fuse the feedstock layer by layer into a part 1 . This fusion is attributed to the melting or sintering of the components present in the feedstock, where melting includes heating, liquid conversion, fusion, and solidification, and sintering includes heating and fusion without liquid conversion [2][3][4] . Thereby, a 3D printing process utilizing a laser source meant to sinter is known as selective laser sintering (SLS) 5 .…”

Section: Introductionmentioning

confidence: 99%

Selective Laser Sintering of a Photosensitive Drug: Impact of Processing and Formulation Parameters on Degradation, Solid-State, and Quality of 3D Printed Dosage Forms

Thakkar¹,

Davis²,

Williams³

et al. 2021

Preprint

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This research study utilized a light-sensitive drug, nifedipine (NFD), to understand the impact of processing parameters, and formulation composition on drug degradation, crystallinity, and quality attributes (dimensions, hardness, disintegration time) of selective laser sintering (SLS) based 3D printed dosage forms. Selective laser sintering (SLS), in most cases, uses an ultraviolet laser source, and drugs tend to absorb radiation at varying intensities around this wavelength (455 nm). This phenomenon may lead to chemical degradation, and solid-state transformation, which was assessed for nifedipine in formulations with varying amounts of vinyl pyrrolidone-vinyl acetate copolymer (Kollidon® VA 64) and potassium aluminum silicate-based pearlescent pigment (Candurin®), processed under different SLS conditions in the presented work. After preliminary screening Candurin®, surface temperature (ST), and laser speed (LS) were identified as the significant independent variables. Further, using the identified independent variables a 17-run, randomized, Box-Behnken design was developed to understand the correlation trends and quantify the impact on degradation (%), crystallinity, quality attributes (dimensions, hardness, disintegration time) employing qualitative and quantitative analytical tools. The design of experiments (DoE) and statistical analysis observed that LS and Candurin® (%wt) had a strong negative correlation on drug degradation, hardness, and weight, whereas ST had a strong positive correlation with, drug degradation, amorphous conversion, and hardness of the 3D printed dosage form. From this study, it can be concluded that formulation and processing parameters have a critical impact on stability and performance; hence these parameters should be evaluated and optimized before exposing light-sensitive drugs to the SLS processes.

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Section: Introductionmentioning

confidence: 99%

Selective Laser Sintering of a Photosensitive Drug: Impact of Processing and Formulation Parameters on Degradation, Solid-State, and Quality of 3D Printed Dosage Forms

Thakkar¹,

Davis²,

Williams³

et al. 2021

Preprint

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“…The formation mechanism of this defect is elaborated in Section 4.3. Oliveira, Lalonde, and Ma (2020) proposed the reduction in the hatch distance or layer thickness to increase the laser beam penetration depth and suppress the defects caused by the lack of fusion.…”

Section: Lack Of Fusion and Element Segregationmentioning

confidence: 99%

Recent progress and scientific challenges in multi-material additive manufacturing via laser-based powder bed fusion

Wei¹,

Li²

2021

Virtual and Physical Prototyping

158

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Multi-material additive manufacturing provides a new route for fabricating components with tailored physical properties. Laser-based powder bed fusion (L-PBF), also known as selective laser melting, is a powder bed-based additive manufacturing technology. This technology affords the advantage of manufacturing metallic and non-metallic materials with high geometrical resolution. An emerging field relevant to the foregoing is multi-material L-PBF. This paper reviews the latest progress in this field including multiple material powder deposition mechanisms, molten pool behaviour, process characteristics of printing metal-metal, metal-ceramic, and metal-polymer multiple material components, and potential applications. Finally, scientific and technological challenges are presented.

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“…An insufficient laser power as a rule leads to the formation of unmolten defects (lack-of-fusion porosity region in Figure 2 ). Too slow a scanning speed, in turn, leads to keyhole porosity, while too high an ED initiates the balling effect [ 88 , 89 ], as well as boiling and evaporation of the melt (discussed in detail in Section 4 ). It does not mean that optimal SLM regimes must lie within the process window; on the contrary, an optimal P–V ratio could even go out of the frame of the overall window shown because of other factors such as powder morphology, layer thickness, hatch spacing, and scanning strategy.…”

Section: Slm Regimes Process Window and Microstructurementioning

confidence: 99%

Selective Laser Melting of Al-Based Matrix Composites with Al2O3 Reinforcement: Features and Advantages

et al. 2021

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Aluminum matrix composites (AMC) are of great interest and importance as high-performance materials with enhanced mechanical properties. Al2O3 is a commonly used reinforcement in AMCs fabricated by means of various technological methods, including casting and sintering. Selective laser melting (SLM) is a suitable modern method of the fabrication of net-shape fully dense parts from AMC with alumina. The main results, achievements, and difficulties of SLM applied to AMCs with alumina are discussed in this review and compared with conventional methods. It was shown that the initial powder preparation, namely the particle size distribution, sphericity, and thorough mixing, affected the final microstructure and properties of SLMed materials drastically. The distribution of reinforcing particles tends to consolidate the near-melting pool-edges process because of pushing by the liquid–solid interface during the solidification process that is a common problem of various fabrication methods. The achievement of an homogeneous distribution was shown to be possible through both the thorough mixing of the initial powders and the precise optimization of SLM parameters. The strength of the AMCs fabricated by the SLM method was relatively low compared with materials produced by conventional methods, while for superior relative densities of more than 99%, hardness and tribological properties were obtained, making SLM a promising method for the Al-based matrix composites with Al2O3.

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Processing parameters in laser powder bed fusion metal additive manufacturing

Cited by 571 publications

References 74 publications

Selective Laser Sintering of a Photosensitive Drug: Impact of Processing and Formulation Parameters on Degradation, Solid-State, and Quality of 3D Printed Dosage Forms

Selective Laser Sintering of a Photosensitive Drug: Impact of Processing and Formulation Parameters on Degradation, Solid-State, and Quality of 3D Printed Dosage Forms

Recent progress and scientific challenges in multi-material additive manufacturing via laser-based powder bed fusion

Selective Laser Melting of Al-Based Matrix Composites with Al2O3 Reinforcement: Features and Advantages

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