3D printing materials

AM Processes and working Principles

Rapid Freeze Prototyping (RFP)
Freeze-form Extrusion Fabrication (FEF)
Stereolithography (SLA)
Multi-jet modeling (MJM)
Laminated object manufacturing (LOM)
Fused deposition modeling (FDM)
Laser metal deposition (LMD)
Electron beam melting (EBM)
Selective laser sintering (SLS)
Direct metal laser sintering (DMLS)
A polymer is a large molecule, or macromolecule, composed of many
repeated subunits. Due to their broad range of properties, both
synthetic and natural polymers play essential and ubiquitous roles in
everyday life. Polymers range from familiar synthetic plastics such as
polystyrene to natural biopolymers such as DNA and proteins that are
fundamental to biological structure and function. Polymers, both
natural and synthetic, are created via polymerization of many small
molecules, known as monomers. Their consequently large molecular
mass relative to small molecule compounds produces unique physical
properties, including toughness, viscoelasticity, and a tendency to
form glasses and semicrystalline structures rather than crystals.
A metal is a material that, when freshly prepared, polished, or
fractured, has a lustrous appearance, and conducts both electricity and
heat relatively well. Metals are typically malleable (they can be
hammered into thin sheets) or ductile (can be drawn into wires). A
metal may be a pure chemical element such as gold, or an alloy of
variable composition such as stainless steel, or an alloy of fixed
composition, otherwise known as an intermetallic compound, such as
one of the nickel aluminides, Ni3Al, NiAl, or NiAl3. Most elemental
metals are denser than other elements; iron, for example, is heavier
than carbon, and sulfur.
Atoms of metals readily lose their outer shell electrons, resulting in a
free flowing cloud of electrons throughout the metallic lattice. The
solid state of the metal is the net result of electrostatic interactions
between each atom and the electron cloud. This type of interaction is
called a metallic bond.
 A ceramic is a non-metallic solid material comprising an inorganic
compound of metal, non-metal or metalloid atoms primarily held
in ionic and covalent bonds

A composite material (also called a composition material or

shortened to composite, which is the common name) is a material
made from two or more constituent materials with significantly
different physical or chemical properties that, when combined,
produce a material with characteristics different from the individual
components. The individual components remain separate and distinct
within the finished structure, differentiating composites from mixtures
and solid solutions.
How to make filament for 3D printing
How to make sheets for 3D printing
How to make powders for 3D printing
How AM powders are made?

Gas Atomisation:

The feedstock is melted under an air or inert gas or in a vacuum atmosphere; then,
the chamber is back-filled with gas to force molten alloy through a nozzle. High-
velocity gas (air, nitrogen, helium or argon) gas impinges into the flowing melt and
breaks it up into fine droplets.

Interfacial tensions naturally spheroidise the surface of molten metal droplets that
cool down and fall at the bottom of the atomization tower, where powders are
collected. Gas atomization technology provides qualified powders for various
additive manufacturing processes, such as selective laser melting (SLM), electron
beam melting (EBM), direct energy deposition (DED) and infiltration.

Gas Atomisation is mostly used for Fe, Ni and Co alloys, but is also available for Al
and Ti alloys
Other variations of this techniques:

Water atomization: for unreactive materials, produces irregular shaped particles.

Plasma atomization: high-quality and extremely spherical powder, limited to alloys that can
be formed into a wire feedstock.

Electrode induction melting gas atomisation: suitable for all alloys, but most economic with
reactive alloys like Ti. A bar feedstock is rotated and melted by an induction coil before it
flows downwards into a gas stream for atomisation. A cheap, clean, and good process for
small batches and to produce small diameter powder particles.

Centrifugal atomisation: Good trade-off between Gas atomisation and Plasma atomisation,
best suited to larger batch sizes of less reactive, low-melting temperature alloys; however, it
can also produce Ni-base superalloy powders.
After production, powders can be characterized according to various
standard techniques used for granular materials:
•Hall flow: Flow rate and apparent density.
•Powder flow and rheological properties analysis.
•Angle of repose: Steepest angle of descent to which powders are
piled without slumping.
•Tapped density: Bulk density of the powder after
consolidation/compression.
•Morphology by scanning electron microscopy.
•Entrapped porosity by scanning electron or optical microscopy.
•Laser diffraction: Analysis of the particle size.
•Sieve analysis: Assess the particle size distribution.
•Moisture determination: water mechanically held water on the
surface or between the particles of the material.
•Chemical composition analysis: amount of metallic, non-metallic
impurities (elemental form, or in dissolved form as solid solution or
as compounds).
What makes a powder suitable?

Metal powders used in additive manufacturing should have:

Spherical shape to ensure good flow/coating ability and a high packing density,

Particle size usually below 50 μm or 150 μm depending on machine type and surface
finish or productivity required.

Particle size distribution tailored to the application and properties.

Controlled chemical composition and gas content.

Low porosity, fine microstructure and uniform properties