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<p>Reliable powder bed formation is fundamental to binder jet additive manufacturing, yet the particle-scale mechanisms governing complex spreading processes remain insufficiently understood, particularly for coarse and irregular particles. This study investigates sand-based binder jet manufacturing by combining powder spreading experiments with discrete element method simulations to systematically examine the effects of layer thickness, spreading speed, and roller rotation on particle behavior and powder bed quality. Results indicate that, during the transition from powder pile to powder layer, particle velocity and force states in the transitional region jointly control packing density and surface quality. Furthermore, particles in the pre-laid layer are reactivated under roller action and participate in the formation of new layers, with their buffering and constraining effects significantly influencing particle rearrangement and densification patterns. Distinct responses are observed for different sand types due to variations in particle size and roundness, revealing the coupled mechanisms between particle characteristics, process parameters, and powder bed quality. These findings provide insights for optimizing processes in sand-based and other coarse-particle powder bed additive manufacturing.</p>

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Particle dynamics in roller-based powder spreading and impact on powder bed quality in binder jet additive manufacturing

  • 期刊论文

  • 发表日期：

    2026年6月25日

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  • Haoming Shi,
  • Haoqin Yang,
  • Zhongde Shan,
  • Dandan Yan,
  • Jian Huang,
  • Tianxiong Hu,
  • Jun Wang,
  • Yajun Yin

摘要

Reliable powder bed formation is fundamental to binder jet additive manufacturing, yet the particle-scale mechanisms governing complex spreading processes remain insufficiently understood, particularly for coarse and irregular particles. This study investigates sand-based binder jet manufacturing by combining powder spreading experiments with discrete element method simulations to systematically examine the effects of layer thickness, spreading speed, and roller rotation on particle behavior and powder bed quality. Results indicate that, during the transition from powder pile to powder layer, particle velocity and force states in the transitional region jointly control packing density and surface quality. Furthermore, particles in the pre-laid layer are reactivated under roller action and participate in the formation of new layers, with their buffering and constraining effects significantly influencing particle rearrangement and densification patterns. Distinct responses are observed for different sand types due to variations in particle size and roundness, revealing the coupled mechanisms between particle characteristics, process parameters, and powder bed quality. These findings provide insights for optimizing processes in sand-based and other coarse-particle powder bed additive manufacturing.