Granular Powder for Additive Manufacturing Fluidity
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Solution Overview
Problem
Conventional powder additive manufacturing techniques face challenges in achieving high fluidity and uniformity of powder materials, particularly for metal and ceramic materials, which affects the quality and surface smoothness of 3D objects.
Innovation Solution
The development of a highly fluid powder material formed from secondary particles with primary particles bound three-dimensionally, allowing for improved fluidity and uniformity, and a method for forming 3D objects using these materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional powder materials (metal or ceramic) are used in powder additive manufacturing, then the material strength and functional properties are improved, but the fluidity and uniformity of the powder deteriorate, affecting surface smoothness and manufacturing quality
Solution Approach 1:
The invention segments the powder particles into specific size ranges (10-50 μm optimal range) and controls the particle size distribution to ensure both fluidity and strength. By dividing the powder into discrete size categories and optimizing the distribution within these ranges, the patent achieves improved flow properties while maintaining material integrity for additive manufacturing
Solution Approach 2:
The invention changes the physical parameters of the powder material by controlling particle size (10-50 μm), shape (sphericity 0.8-1.0), and size distribution (narrowed about d50%). These parameter optimizations resolve the contradiction by creating powder that flows uniformly while maintaining the strength required for functional 3D objects
2Manufacturing precision
If powder materials with high fluidity are used to improve layer uniformity, then the surface smoothness is improved, but the material may lack the necessary strength and functional properties for practical applications
Solution Approach 1:
The invention applies local quality by optimizing specific properties of the powder particles - sphericity (0.8-1.0) and size distribution (narrowed about d50%) - to achieve uniform flow and smooth surfaces in critical areas, while the overall particle composition maintains the strength required for functional applications. Different regions of the powder bed receive optimized characteristics appropriate to their manufacturing requirements
3Ease of operation
If resin materials are used for powder additive manufacturing, then the fluidity and ease of processing are improved, but the high temperature resistance and strength required for practical applications are lost
Solution Approach 1:
The invention changes the material parameter from resin-based powders to metal or ceramic powders with optimized physical characteristics (size 10-50 μm, sphericity 0.8-1.0). This parameter change enables the material to withstand high temperatures while the controlled particle morphology maintains the fluidity and processability needed for additive manufacturing operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The proposed solution provides a highly fluid powder material that enhances the quality and surface smoothness of 3D objects, improving the efficiency and precision of the powder additive manufacturing process.
Implementation Method 1
granulated and sintered particles
Data Source
Figure 1~2
AI summary
[Problem] To provide a powder material that has good fluidity and is used for powder additive manufacturing. [Solution] The powder material of this invention is used in powder additive manufacturing. The powder material is formed of particles having a form of secondary particles that are formed with primary particles bound three-dimensionally with interspaces. The secondary particles forming the powder material preferably have an average particle diameter of 1 µm or larger, but 100 µm or smaller. The secondary particles forming the powder material are preferably granulated particles. The powder additive manufacturing method of this invention is carried out, using the powder material.