Particle Generation to Minimize the Computing Time of the Discrete Element Method for Particle Packing Simulation

There are computation time constraints caused by the number and size of particles in the powder packing simulation using DEM. In this paper, newly suggested packing model transforms a general packing sequence –particle generation, stack, and compression – into particle generation and packing by growing particles. To verify the new packing model, it was compared using three contact models widely used in DEM, in terms of Radial Distribution Function, porosity, and Coordination Number. As a result, contact between particles showed a similar trend, and the pore distribution was also similar. Using the new packing model can reduce simulation time by 400% compared to the normal packing model without any other coarse graining methods. This model has only been applied to particle packing simulations in this paper, but it can be expanded to other simulations with complex domain based on DEM.

Discrete-Element Simulation of Powder Spreading Process in Binder Jetting, and the Effects of Powder Size

Binder Jetting has gained particular interest amongst Additive Manufacturing (AM) techniques because of its wide range of applications, broader feasible material systems, and absence of rapid melting-solidification issues present in other AM processes. Understanding and optimizing printing parameters during the powder spreading process is essential to improve the quality of the final part. In this study, a Discrete Element Method (DEM) simulation is employed to evaluate the powder packing density, flowability, and porosity during powder spreading process utilizing three different powder groups. Two groups are formed with monoidal size distributions (75–84 μm and 100–109 μm), and the third one consisting of a bimodal distribution (50 μm + 100 μm). A thorough investigation into the effects of powder size distribution during the powder spreading step in a binder jetting process is conducted using ceramic foundry sand. It was observed that coarser particles result in higher flowability (62% decrease in repose angle) than finer ones due to the cohesion effect present in the latter. A bimodal size distribution yields the highest packing density (8% increase) and lowest porosity (∼12% reduction) in the powder bed, as the finer particles fill in the voids created between the coarser ones. Findings from this study are directly applicable to binder-jetting AM process, and also offer new insights for AM powder manufacturers.

Influence of packing density and fillers on thermal conductivity of polymer powders for additive manufacturing

Additive manufacturing of polymer powders is nowadays an industrial production technology. Complex thermal phenomena occur during processing, mainly related to the interaction dynamics among laser, powder, and heating system, and also to the subsequent cool-down phase from the melt to the parts. Thermal conductivity of the powder is a key property for material processing, since an inhomogeneous temperature field in the powder cake leads to uneven part properties and can strongly limit productivity because only a smaller portion of the build chamber can be used. Nevertheless, little is known about the relationship between thermal conductivity, packing density, and presence of fillers, which are used to enhance specific properties such as high temperature resistance or stiffness. The development and consequent validation of a device capable of measuring thermal conductivity as a function of powder packing density are then extremely important, providing an additional tool to characterize powders during the development process of new materials for PBF of polymers. The results showed a positive correlation between packing density and thermal conductivity for some commercially available materials, with an increase of the latter of about 10 to 40% with an increase of the packing density from 0 to 100%. Problems arose in trying to replicate the compaction state of the powder, since the same amount of taps led to a different packing density, but this is a known problem of measuring free-flowing powders such as the ones used for additive manufacturing. Regarding fillers, an increase of about 40 to 70% of thermal conductivity when inorganic fillers such as carbon fibers are added to the neat polymer was observed, and the expected behavior following the rule of mixture was only partially observed.

Crystallographic tomography and molecular modelling of structured organic polycrystalline powders

Novel combination of crystallographic tomography and molecular modelling is used to examine the powder packing behaviour and crystal interactions for an organic polycrystalline powder bed.

DEM based investigation of powder packing in 3D printing of pharmaceutical tablets

3D printing is emerging as one of the most promising methods to manufacture Pharmaceutical dosage forms as it offers multiple advantages such as personalization of dosage forms, polypill, fabrication of complex dosage forms etc. 3D printing came into existence in 1980s but its use was extended recently to pharmaceutical industry along with the approval of first 3D printed tablet Spritam by FDA in 2015. Spritam was manufactured by Aprecia pharmaceuticals using binder jetting technology. Binder jet 3D printing involves a hopper for powder discharge and printheads for ink jetting. The properties of tablets are highly dependent upon the discharge quality of powder mixture from the hopper and jetting of the ink/binder solution from the printhead nozzle. In this study, numerical models were developed using Discrete element method (DEM) to gain better understanding of the binder jet 3D printing process. The DEM modeling of hopper discharge was performed using in-house DEM code to study the effect of raw material attributes such as powder bed packing density (i.e. particle size, particle density etc) on the printing process, especially during powder bed preparation. This DEM model was further validated experimentally, and the model demonstrated good agreement with experimental results.

Study of Droplet Diffusion in Hydrothermal-Assisted Transient Jet Fusion of Ceramics

Hydrothermal-assisted transient jet fusion (HTJF) is a powder-based additive manufacturing (AM) method of ceramics, which utilizes a water-mediated hydrothermal mechanism to fuse particles together, eliminating the use of organic binders in forming green bodies and thereby contributing to high green-density parts (>90%) advantageous for fabricating functional materials with high performance. In the HTJF process, a transient solution such as water is selectively deposited into a powder bed in a layer-by-layer fashion followed by a hydrothermal fusion process. Upon the ejection and deposition of a droplet of the transient solution on the surface of the powder bed, the diffusion behavior of the liquid significantly influences the particle fusion and the fabrication accuracy of the HTJF process. Precise control of the liquid diffusion in the powder bed is critical for the fabrication of ceramic structures with both high density and accuracy. In this paper, the dependence of transient solution diffusion on different process parameters (i.e., powder packing density, droplet size, pressure, etc.) in the HTJF process were studied. Both numerical modeling and experimental methods were used to quantify the relationships between processing parameters and diffusion profiles of transient solution droplets (e.g., diffusion width/depth). Optimum processing conditions were identified to mitigate the undesired diffusion of transient solution droplets in the powder bed.