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Powder Spreading Dynamics and Process Optimization at a Heterogeneous Interface for Z-Direction Multi-Material Laser
Zhaowei Xiang1, Shuai Ma1, Fulin Han1
1School of Mechanical Engineering, Chongqing University of Technology, Chongqing 400054, China.
Materials (Basel, Switzerland)
|May 13, 2026
Summary
Optimizing multi-material 3D printing involves understanding powder spreading dynamics. Higher layer thickness improves powder bed quality, while higher spreading speed enhances efficiency, allowing for synergistic optimization.
Area of Science:
- Materials Science
- Mechanical Engineering
- Additive Manufacturing
Background:
- Multi-material additive manufacturing requires precise control over powder spreading.
- Heterogeneous interfaces present unique challenges in powder bed formation.
Purpose of the Study:
- To investigate the powder spreading dynamics at Z-direction heterogeneous material interfaces.
- To analyze the effects of spreading speed and layer thickness on powder bed quality.
Main Methods:
- Developed a discrete element model (DEM) to simulate powder spreading.
- Focused on 316L stainless steel and CuCrZr materials.
- Systematically examined the influence of spreading parameters.
Main Results:
- Observed unsteady powder motion and fluctuating inter-particle forces at heterogeneous interfaces.
- Increased spreading speed degraded powder distribution and deposited mass.
- Increased layer thickness significantly improved powder bed uniformity and mass deposition.
Conclusions:
- Powder spreading dynamics at heterogeneous interfaces are complex, influenced by material interactions.
- Optimizing spreading speed and layer thickness is crucial for achieving high-quality multi-material powder beds.
- Findings provide a theoretical basis for enhancing multi-material laser powder bed fusion processes.
