From Bettersize Instruments Ltd.Reviewed by Maria OsipovaDec 12 2024 insights from industryBeverly Barnum & Viola ShenSenior Application Scientist & Application ScientistBettersize Instruments
In this interview, AZoMaterials speaks with Beverly Barnum and Viola Shen about the strategies for optimizing additive manufacturing processes.
What is additive manufacturing, and why is it advantageous over traditional manufacturing methods?
Dr. Beverly Barnum: Additive manufacturing, or AM, is a revolutionary technology that creates products layer by layer using a digital 3D model. Unlike traditional manufacturing, which frequently employs subtractive processes such as machining or shaping, AM makes parts by adding material only where necessary.
This technology has various advantages, including less material waste, shorter prototype cycles, and the capacity to create complicated geometries that would be unfeasible or prohibitively expensive using standard methods.
For example, industries such as aerospace and healthcare benefit substantially from this adaptability. In aerospace, lightweight, tailored components can increase fuel efficiency and performance, while in healthcare, additive manufacturing allows for the manufacture of highly individualized goods such as prostheses or dental implants.
In addition, AM's ability to reduce upfront tooling costs makes it perfect for small-batch production and rapid design iteration. It is certainly a game changer in a variety of businesses.
Why is particle analysis crucial in additive manufacturing, and what are the key parameters to consider?
Dr. Beverly Barnum: Particle analysis is critical for guaranteeing the quality and uniformity of items manufactured using AM. To work best, the powdered materials employed in these processes must meet precise size, shape, and distribution parameters, whether they are metals, polymers, ceramics, or composites.
For example, consistent particle size ensures uniform layer deposition during printing, whereas particle shape affects flowability and packing density.
Other crucial characteristics include density and surface area. These affect the particles' thermal characteristics, reactivity, and sintering behavior. If any of these properties are not maximized, the final item may contain faults such as inadequate fusion, surface roughness, or structural weaknesses.
By studying and regulating these variables, manufacturers may greatly enhance process reliability and final product quality.
How does particle size distribution impact the additive manufacturing process?
Dr. Beverly Barnum: Particle size distribution, or PSD, is critical to additive manufacturing because it directly affects material flowability, packing behavior, and even the mechanical qualities of the completed product.
A narrow PSD produces more uniform layer deposition, which is essential for creating smooth surfaces and consistent part strength. A broader PSD, on the other hand, can be useful in applications that demand a high packing density since smaller particles can fill the gaps between bigger ones.
It is very important to find a balance. If the particles are too fine, they may cluster together or flow irregularly, disrupting the printing process. In contrast, if the particles are excessively large, they may interfere with the final product's resolution and surface polish. Understanding the exact requirements of your AM process and adapting the PSD properly is critical to attaining the best results.
Image Credit: Bettersize Instruments Ltd.
Could you clarify how Bettersize Instruments addresses particle analysis issues in AM applications?
Viola Shen: Bettersize Instruments has created advanced technologies to address the challenges of particle analysis in additive manufacturing. Our devices, such as the Bettersizer 2600 and PowderPro A1, provide detailed information on the crucial parameters that determine AM performance.
The Bettersizer 2600, for example, integrates laser diffraction with dynamic image processing. This allows it to measure particle size distribution and shape in the same test. Such dual analysis is necessary because size and shape frequently interact to impact flowability and packing efficiency.
Similarly, the PowderPro A1 provides a small solution for evaluating parameters such as tapped density, compressibility, and flowability in a single device. This integration saves time and gives producers a more comprehensive picture of powder behavior, allowing them to make data-driven adjustments for better results.
How does the Bettersizer 2600 utilize laser diffraction and dynamic image processing to improve particle characterization?
Viola Shen: The Bettersizer 2600 performs laser diffraction using a patented optical technology that analyzes light scattering patterns to determine particle size distribution. This approach is rapid, accurate, and applicable to a wide range of particle sizes.
What distinguishes the Bettersizer 2600 is its ability to integrate with the PIC-1 dynamic image analysis module. This combination allows for simultaneous investigation of particle shape and size -- a feature that is especially useful in AM, where both parameters are crucial.
For example, in a case study involving metallic particles, the Bettersizer 2600 was utilized to assess multiple samples. We discovered that particles with larger circularity values -- basically more spherical particles -- had superior flowability and layer deposition uniformity.
These findings assisted in optimizing the powder feedstock for increased performance. Due to its dual functionality, the Bettersizer 2600 is an effective tool for dealing with the complexities of AM operations.
Why is accurate density estimation crucial in additive manufacturing, and how does the BetterPyc 380 gas pycnometer work?
Viola Shen: True density is an important parameter in AM because it influences material homogeneity, interlayer adhesion, and the mechanical qualities of the completed product. Inconsistent density can cause faults in the final structure, such as cavities or weak areas.
The BetterPyc 380 gas pycnometer addresses this issue by accurately measuring the volume of a sample using gas displacement. It uses Boyle's Law to compute accurate density based on the pressure-volume relationship in a sealed chamber. This approach is non-invasive and highly accurate, making it appropriate for delicate or porous materials commonly used in additive manufacturing.
In addition, the BetterPyc 380 is compatible with a wide range of materials and can function in a variety of temperatures. It is especially successful in areas like aerospace and medical manufacturing, where high-quality standards are required.
What are the common challenges in maintaining consistent particle quality during the additive manufacturing process?
Dr. Beverly Barnum: Maintaining consistent particle quality is no easy task. One of the most difficult issues is ensuring consistency in size, shape, and surface features, as even little differences can affect flowability and packing behavior. Another difficulty is contamination, which can occur from external sources or during material handling and cause faults in the final product.
Storage conditions also play an important role. Powders are sensitive to environmental conditions such as humidity, which can cause particles to stick together or disintegrate over time. These dangers can be reduced by ensuring correct storage and doing frequent quality control inspections with tools such as the PowderPro A1 and Bettersizer 2600. These tools enable firms to monitor and alter their operations to ensure that high-quality standards are regularly met.
Are there any real-world examples where improving particle properties made a big difference in product quality?
Dr. Beverly Barnum: In the aerospace industry, improving particle size and shape has resulted in significant improvements in mechanical characteristics and fatigue life -- both of which are crucial for components exposed to harsh environments. For example, producers have improved layer adhesion and reduced material waste by using powders with a narrow PSD and high circularity.
Similarly, in the medical field, careful control over particle properties has improved the strength and surface polish of personalized implants. These enhancements not only save production costs but also ensure the reliability and lifetime of the finished goods, which is especially crucial in high-risk industries like aerospace and healthcare.
About the Speakers Dr. Beverly Barnum
Dr. Beverly Barnum is a senior application scientist at Bettersize Instruments with extensive expertise in advancing technological solutions. She holds a Bachelor of Science degree in Chemistry from California State University and a Ph.D. in Inorganic Chemistry from the University of Pennsylvania.
Recognized for her innovative problem-solving skills, Dr. Barnum is a highly accomplished scientist dedicated to pushing the boundaries of particle characterization and analysis.
Viola Shen
Viola Shen is an application scientist at Bettersize Instruments, specializing in powder characterization and particle size analysis using advanced light scattering techniques.
She earned her master's degree in chemical engineering from the University of Southern California. At Bettersize, Viola focuses on optimizing particle analysis methods, contributing to innovations in the advanced materials industry.
This information has been sourced, reviewed and adapted from materials provided by Bettersize Instruments Ltd.
For more information on this source, please visit Bettersize Instruments Ltd.
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