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Understanding the Reusability of Ti6Al4V Powder in Laser Powder Bed Fusion.

Nathaniel W Zuckschwerdt1, Amit Bandyopadhyay1

  • 1W. M. Keck Biomedical Materials Research Lab, School of Mechanical and Materials Engineering, Washington State University, Pullman, Washington, 99146-2920, USA.

Engineering Science in Additive Manufacturing
|January 12, 2026
PubMed
Summary

Powder reused in laser powder bed fusion (L-PBF) degrades, increasing lack-of-fusion pores in parts. Particle size distribution shifts, reducing reusable powder over multiple prints.

Keywords:
3D PrintingAdditive manufacturingLPBFPowder degradationTi6Al4V

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Area of Science:

  • Materials Science
  • Additive Manufacturing
  • Powder Metallurgy

Background:

  • Powder quality is critical for successful laser powder bed fusion (L-PBF) manufacturing.
  • Understanding powder degradation during reuse is essential for process optimization and cost-effectiveness.

Purpose of the Study:

  • To investigate the effects of powder degradation on part quality in L-PBF.
  • To identify specific powder property changes that lead to defects in finished components.

Main Methods:

  • Utilized powder samples subjected to multiple L-PBF print cycles.
  • Analyzed changes in powder particle size distribution before and after printing.
  • Quantified the increase in defective particles and oversized particles (>63μm).

Main Results:

  • Reused powder significantly increased the occurrence of lack-of-fusion (LOF) pores in printed parts.
  • Powder degradation was characterized by an increase in larger particle sizes and a decrease in smaller particle sizes.
  • An 11% increase in defective particles and a ~2% increase in particles >63μm were observed over five print cycles, limiting powder reusability.

Conclusions:

  • Powder degradation directly impacts L-PBF part quality, primarily through increased LOF defects.
  • Changes in particle size distribution are the key mechanism driving powder quality decline and reduced reusability.
  • This study provides insights into determining the effective lifespan of powder in L-PBF processes.