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Localized Particle Segregation Induced by Leidenfrost Droplet Motion across Superheated Powder Bed.

Kimberly Kellyanne Tan¹, Thien-Binh Nguyen¹, Chang Quan Lai^1,2

¹School of Mechanical and Aerospace Engineering, Nanyang Technological University, 50 Nanyang Ave, Singapore 639798, Singapore.

Langmuir : the ACS Journal of Surfaces and Colloids

|February 16, 2026

Summary

Leidenfrost droplets can locally segregate particles in powder beds for additive manufacturing. This method enables site-specific properties in metallic parts by controlling particle size distribution.

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Area of Science:

Materials Science
Additive Manufacturing
Fluid Dynamics

Background:

Mechanical properties of additively manufactured metallic parts depend on powder bed particle size distribution.
Localized modification of particle size distribution is needed for heterogeneous metallic parts with site-specific properties.
Current methods for localized particle segregation are limited.

Purpose of the Study:

To demonstrate a simple method for localized particle segregation in powder beds using Leidenfrost droplets.
To investigate the parameters influencing particle segregation and deposition patterns.

Main Methods:

Utilizing Leidenfrost droplets traveling at a constant speed to fluidize and segregate powder particles.
Analyzing the effect of powder bed thickness, droplet velocity, and fluid type (water vs. ethanol) on particle segregation.
Quantifying the deposition of larger particles based on varying initial particle proportions.

Main Results:

Leidenfrost droplets effectively segregate particles, with larger particles preferentially deposited in the droplet's wake.
Increased powder bed thickness and slower droplet velocity enhance the deposition of larger particles.
Changing the fluid to ethanol reduced fluidization velocity, promoting further segregation, especially at lower powder bed thicknesses.

Conclusions:

Leidenfrost droplets offer a promising technique for localized particle segregation in powder beds.
This method allows for the fabrication of heterogeneous metallic parts with tailored, site-specific properties.
The study highlights the potential for advanced additive manufacturing through controlled particle size distribution.