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Related Experiment Video

Updated: Jul 16, 2026

Fused Filament Fabrication (FFF) of Metal-Ceramic Components
08:43

Fused Filament Fabrication (FFF) of Metal-Ceramic Components

Published on: January 11, 2019

A Multi-Physics Modeling Framework for Optimizing Spreading and Sintering Parameters in Powder Bed Fusion.

Jiang Li1, Fulun Peng1, Jianzhao Zhao1

  • 1Xi'an Institute of Applied Optics, Reconnaissance Vehicle Research and Development Center, Xi'an 710065, China.

Polymers
|July 15, 2026
PubMed
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Optimizing Powder Bed Fusion-Laser Beam/Polymer (PBF-LB/P) for composites is challenging. This study uses modeling to define process windows for powder spreading and sintering, improving material properties.

Area of Science:

  • Additive Manufacturing
  • Materials Science
  • Computational Modeling

Background:

  • Powder Bed Fusion-Laser Beam/Polymer (PBF-LB/P) is vital for aerospace applications.
  • Optimizing PBF-LB/P for thermoplastic composites faces challenges due to powder flow and melting instability.
  • Existing methods struggle to define reliable process parameters for composite PBF-LB/P.

Purpose of the Study:

  • To develop and validate discrete element and finite element models for determining PBF-LB/P process windows.
  • To systematically optimize powder spreading and sintering stages for thermoplastic composites.
  • To enhance the reliability and performance of PBF-LB/P processed materials.

Main Methods:

  • Developed discrete element and finite element models for powder spreading and sintering simulation.
Keywords:
PEEK/carbon fiber compositesdiscrete element method and finite element methodpowder bed fusionpowder spreading and laser sinteringprocess window optimization

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Last Updated: Jul 16, 2026

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  • Evaluated powder layer performance using surface profile, density, and uniformity metrics.
  • Analyzed effects of reinforcement, spreading speed, layer thickness, laser power, scanning speed, and hatching space.

    • Main Results:

    • Established optimal layer thicknesses: 0.13 mm for PEEK and 0.12 mm for PEEK/CF composite.
    • Defined reliable spreading and sintering parameter windows for PBF-LB/P.
    • Achieved 99.31% relative density and 13.1% higher tensile strength for PEEK specimens within the optimized window.

    Conclusions:

    • The developed modeling approach effectively determines optimal PBF-LB/P process windows for thermoplastic composites.
    • Optimized process parameters significantly enhance material density and mechanical properties.
    • This work provides a systematic methodology for reliable PBF-LB/P of advanced composite materials.