(310d) Development of a Novel Powder Patterning Method for Functionally Graded 3D Printing

Current powder-based 3D printing methods like selective laser sintering (SLS) and binder jetting (BJT) create functional gradients by adjusting process parameters such as the laser power, raster speed, liquid binder formulation, and local binder amount. However, they generally lack the ability to vary the powder composition on demand for creating heterogenous, functionally graded composites. In this presentation, we will share our latest research in developing a novel powder patterning method capable of selectively depositing various polymer and metal powders without using a liquid carrier or solvent. The method aims to: (i) address unmet needs in patterning the print powders for SLS and BJT, (ii) save materials by depositing powders only where needed, reducing usage and reclaim, and (iii) enable solvent-free processing to avoid liquid removal that consumes energy and to prevent unwanted property changes due to thermal history. In addition to the tool design, the basic working principle of this method and powder requirements will be discussed.