Size and shape of metal powders for additive manufacturing

In this application note, Microtrac MRB provides information on the size and shape analysis of metal powders for additive manufacturing. The term “additive manufacturing” describes a process in which digital 3D design data, typically generated by computer-aided design (CAD), are used to build a component layer by layer by depositing material. Additive manufacturing, also widely known as “3D printing”, is a red-hot topic for R&D departments and small-scale production companies alike. Many manufacturers offer 3D printers or systems for additive manufacturing based on a variety of technologies and materials, for example in automotive, aerospace, defense, food, jewelry, medicine, and many other industries. Some of these methods have matured from a development tool for rapid prototyping to a standard production method.

The basis for most of the above-mentioned processes is a powder bed on which material is sequentially deposited. Depending on the desired specifications of the 3D components, different types of powders are employed in the printing process. The particle size distribution and shape of the powders is a critical parameter for the operating conditions of the printer and for the properties of the final product. The size distribution (average size, as well as the amount of dust and the number of oversized particles) but also the shape of the particles has a strong influence on the flow behavior of the powders.