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<p>Creating layers consisting of multiple material regions in Powder Bed Fusion Additive Manufacturing processes is not possible to date on the commonly employed single recoater-based powder deposition systems. This work presents a novel area segmentation method based on the dual contour gauge design achieving 3D multi-material powder deposition. The method is defined through a computational geometry algorithm based on the notions of Border Curves enclosing Pattern Features and being embedded in minimal Bounding Boxes. The algorithm determines iteratively uni-material areas as subsets of Pattern Features delimited between a Left and a Right front. These fronts are sections of Border Curves and constitute the geometric counterparts of physical contour gauges. The fronts are found by tracing rays that are cast from the Left Front curve horizontally, their intersection with Border Curves defining points on the Right Front. In successive iterations the previous Right Front becomes the new Left Front. The same segmentation of the powder bed layer into uni-material regions is adopted in depositing the powder, as demonstrated by a proof-of-concept simplified prototype device that has been built. A second novelty concerns quantitative investigation of the quality of a two-material layer is performed by Discrete Element Method (DEM) simulation. The comparison between the experimental and simulation evaluation of the method proves that it is feasible to create multi-material layers. The feature dimensional accuracy solely depends on the contour gauge blade thickness. Along the deposition direction of the layer some infiltration error was revealed which varied at different heights within a 100&#xa0;μm thick layer. This solely depends on the layer thickness and the angle of repose of the powder and does not scale with the layer length and width, which makes the method promising. The surface quality of the deposited multi-material layer is comparable to the one deposited by uni-material deposition via doctor blade, quality criteria being roughness, skewness and kurtosis of the surface. Future directions towards deploying the method in Powder-Bed fusion machines are presented last.</p>

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A multi-material deposition concept for powder bed fusion additive manufacturing based on a layer area segmentation method by ray-tracing

  • 期刊论文

  • 发表日期：

    2026年1月29日

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  • Panagiotis Avrampos,
  • George-Christopher Vosniakos

摘要

Creating layers consisting of multiple material regions in Powder Bed Fusion Additive Manufacturing processes is not possible to date on the commonly employed single recoater-based powder deposition systems. This work presents a novel area segmentation method based on the dual contour gauge design achieving 3D multi-material powder deposition. The method is defined through a computational geometry algorithm based on the notions of Border Curves enclosing Pattern Features and being embedded in minimal Bounding Boxes. The algorithm determines iteratively uni-material areas as subsets of Pattern Features delimited between a Left and a Right front. These fronts are sections of Border Curves and constitute the geometric counterparts of physical contour gauges. The fronts are found by tracing rays that are cast from the Left Front curve horizontally, their intersection with Border Curves defining points on the Right Front. In successive iterations the previous Right Front becomes the new Left Front. The same segmentation of the powder bed layer into uni-material regions is adopted in depositing the powder, as demonstrated by a proof-of-concept simplified prototype device that has been built. A second novelty concerns quantitative investigation of the quality of a two-material layer is performed by Discrete Element Method (DEM) simulation. The comparison between the experimental and simulation evaluation of the method proves that it is feasible to create multi-material layers. The feature dimensional accuracy solely depends on the contour gauge blade thickness. Along the deposition direction of the layer some infiltration error was revealed which varied at different heights within a 100 μm thick layer. This solely depends on the layer thickness and the angle of repose of the powder and does not scale with the layer length and width, which makes the method promising. The surface quality of the deposited multi-material layer is comparable to the one deposited by uni-material deposition via doctor blade, quality criteria being roughness, skewness and kurtosis of the surface. Future directions towards deploying the method in Powder-Bed fusion machines are presented last.