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3D Printing Powder Optimization is Key to Part Quality, Productivity

Most metal powders used in 3D printing are produced by gas atomization. In this process, a feedstock is melted in a crucible before it is ejected from a nozzle into a high-pressure gas stream. This breaks the molten metal into fine particles, typically under 50 - 150-microns in size.
While the metal powders produced by this process are typically spherically shaped, it is also important to address the porosity of the surface of the powder particles to improve "flowabililty." Otherwise, the powder can clog or slow during the process, affecting the speed and quality of printing.
"For reliable 3D printing production, the powder must flow continuously and smoothly," explains George Paffendorf, Director of Operations at Advanced Powder Solutions (APS), a contract manufacturer with extensive powder expertise. APS is the in-house testing/engineering arm of GEMCO, a leading manufacturer of tumble blending and vacuum tumble drying equipment. "However, uniform powder flow can be inhibited if the particles are rough or porous, which creates more friction."
To eliminate porosity and enhance flowability, a growing number of proactive powder suppliers as well as 3D printer manufacturers are adding a heat treatment step in the manufacturing process that involves tumble dryers to achieve a more consistent, high-quality product.
For instance, APS utilizes advanced vacuum tumble dryers that provides sparging (gas injection) in addition to heat application. With this approach, a perforated tube is positioned under the bed of material and distributes a flow of inert gas such as nitrogen. This helps to circulate heat evenly amid the powder.
"A raw metal powder may have a porous, craggy outer surface," says Paffendorf. "When we heat treat it in a tumble dryer, it closes up the pores so the particle is more spherical and flows more smoothly."
For more info, call 800-654-3626 in the U.S.; Fax 732-733-1175; email sales@okgemco.com; visit okgemco.com; or write to Advanced Powder Solutions at 301 Smalley Ave, Middlesex, NJ 08846.

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