Expanding the capabilities of laser-based powder bed fusion of polymers through the use of electrophotographic powder application

Kopp SP, Medvedev V, Frick T, Roth S (2022)

Publication Language: English

Publication Type: Journal article

Publication year: 2022

Journal

Journal of Laser Applications Laser Institute of America

Original Authors: Sebastian-Paul Kopp, Vadim Medvedev, Thomas Frick, Stephan Roth

Book Volume: 34

Pages Range: 042032

Issue: 4

DOI: 10.2351/7.0000774

Abstract


Generating multimaterial parts, reaching higher efficiency in powder consumption, and decoupling of powder application behavior from powder properties such as powder flowability are key aspects for using electrophotographic powder application (EPA) in laser-based powder bed fusion of polymers (PBF-LB/P). Moreover, EPA allows the layer thickness to be reduced from around 100–150 μm, depending on respective particle size distribution, in the case of conventional doctor blade or roller-based powder application methods to the diameter of the applied polymer particles (typically between 50 and 130 μm). This can have positive effects on the interlayer connection and, therefore, the mechanical properties of the additively manufactured part because less powder volume has to be fused with the already generated underlying part. Moreover, due to the above-mentioned independence of EPA from powder flowability, the addition of flow aids, such as nano silica, can be reduced to a minimum or even avoided completely. This is the first comprehensive study on resulting properties of parts generated by PBF-LB/P using EPA taking into account both the reduction in layer thickness and reduced addition of flow aids. In addition to improving mechanical properties of generated parts, the independence of powder flowability, in particular, offers the possibility of qualifying currently unsuitable materials for PBF-LB/P. For this purpose, besides widely employed polyamide 12 (PA12), a polypropylene (PP) powder is used that is very difficult to process in conventional PBF-LB/P and can only be applied there with the help of flow aids.

Authors with CRIS profile

Sebastian-Paul Kopp Lehrstuhl für Photonische Technologien (LPT) Vadim Medvedev Lehrstuhl für Photonische Technologien (LPT)

Additional Organisation(s)

Erlangen Graduate School in Advanced Optical Technologies (SAOT) Sonderforschungsbereich 814/3 Additive Fertigung Lehrstuhl für Photonische Technologien (LPT)

Related research project(s)

Efficient additive manufacturing of multi-material parts (B6) (SFB 814 (B6)) CRC 814 - Additive Manufacturing (SFB 814) July 1, 2011 - June 30, 2023

Involved external institutions

Bayerisches Laserzentrum gemeinnützige Forschungsgesellschaft mbH (BLZ) DE Germany (DE)

How to cite

APA:

Kopp, S.-P., Medvedev, V., Frick, T., & Roth, S. (2022). Expanding the capabilities of laser-based powder bed fusion of polymers through the use of electrophotographic powder application. Journal of Laser Applications, 34, 042032. https://doi.org/10.2351/7.0000774

MLA:

Kopp, Sebastian-Paul, et al. "Expanding the capabilities of laser-based powder bed fusion of polymers through the use of electrophotographic powder application." Journal of Laser Applications 34 (2022): 042032.

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