3D Printing Metal Powder Distribution for Flowability and Density
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Solution Overview
Problem
Existing 3D printing methods using high melting point metals, such as stainless steel, face challenges in achieving sufficient shaping properties due to inadequate control of particle size distribution and sphericity, leading to agglomeration and difficulty in forming complex structures.
Innovation Solution
A metal powder for 3D printing is developed with controlled particle size distribution, having a maximum peak between 1 μm to 200 μm, a D90-D10 difference of 10 μm or more, and high sphericity of 90% or more, which improves flowability and shaping properties, allowing for the production of high-density shaped articles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal powder with high melting point (stainless steel, tungsten, molybdenum, etc.) is used for 3D printing, then the temperature resistance and strength of the shaped article is improved, but the shaping property deteriorates due to inadequate particle size distribution control
Solution Approach 1:
The patent applies parameter changes by precisely controlling the particle size distribution parameters (D10, D50, D90 values and their relationships) of metal powder to resolve the contradiction between high temperature resistance and shaping property. By optimizing these particle size parameters, the invention enables high melting point metals to achieve adequate shaping properties during 3D printing while maintaining their inherent temperature resistance
Solution Approach 2:
The patent applies preliminary action by pre-controlling the particle size distribution of metal powder before the 3D printing process. The metal powder is manufactured with specific particle size characteristics (D90-D10≥10μm, maximum peak at 1-200μm, sphericity≥90%) in advance, which enables proper flowability and packing density during the printing process, thereby achieving good shaping properties for high melting point metals
2Reliability
If metal powder with high melting point is used for 3D printing, then the durability of the shaped article is improved, but the flowability deteriorates leading to agglomeration
Solution Approach 1:
The patent applies parameter changes by optimizing the particle size distribution parameters (specifically setting D90-D10≥10μm and maximum peak at 1-200μm) to improve flowability while maintaining durability. This parameter optimization prevents agglomeration during handling and printing processes, enabling high melting point metals to exhibit both good flowability and inherent durability
Solution Approach 2:
The patent applies preliminary action by pre-manufacturing metal powder with controlled particle size distribution and high sphericity (≥90%) before use. This preliminary preparation ensures that the metal powder has adequate flowability for handling and printing operations while maintaining the high durability characteristics of high melting point metals
3Strength
If conventional metal powder is used for 3D printing, then the material strength is maintained, but the density of the shaped article deteriorates due to insufficient particle packing
Solution Approach 1:
The patent applies parameter changes by optimizing the particle size distribution parameters (D10, D50, D90 relationships and maximum peak position) to improve particle packing density. By setting specific parameter ranges (maximum peak at 1-200μm, D90-D10≥10μm), the invention achieves better particle arrangement during printing, resulting in higher density shaped articles while maintaining material strength
Solution Approach 2:
The patent applies preliminary action by pre-controlling the particle size distribution of metal powder to have a maximum peak at 1-200μm and D90-D10≥10μm. This preliminary optimization of particle characteristics enables improved packing density during the printing process, achieving high density shaped articles that maintain the inherent strength properties of the base metal
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 metal powder enables the formation of high-density shaped articles with improved flowability and shaping properties, facilitating the creation of complex structures using high melting point metals like tungsten, molybdenum, rhenium, niobium, tantalum, and chromium, even at high temperatures.
Implementation Method 1
irradiated with laser beam or electron beam to be solidified
Implementation Method 2
The molded resin can be melted by laser beam
Implementation Method 3
irradiated with laser beam or electron beam to be solidified
Implementation Method 4
irradiated with laser beam or electron beam to be solidified
Data Source
AI summary
A metal powder for 3D printer includes a plurality of metal particles. A particle size distribution of the plurality of metal particles has a maximum peak within particle diameters of 1 μm to 200 μm. The particle size distribution gives a difference D90−D10 of 10 μm or more between D90 and D10, D90 denoting a particle diameter in which a cumulative percentage is 90% in volume proportion, and D10 denoting a particle diameter in which a cumulative percentage is 10% in volume proportion.