Discrete Element Method Study on Spreading Behaviour of Non-spherical Polymeric Powder in Powder Bed Fusion with Blade and Roller Spreaders

The properties of the spread powder layer are key in Powder Bed Fusion (PBF) additive manufacturing. Higher packing density and a uniform powder layer are vital for part quality. This study examined the impact of blade-shaped and roller-shaped spreading tools on powder behaviour using the Discrete Element Method (DEM). Switching from a blade to a roller at a spreading speed of 30 mm/s improved the packing fraction by 76% and reduced surface roughness by 16%. The roller-shaped tool produced a more effective initial powder layer with a better packing fraction and a smoother surface finish.