A Ternary Model for Particle Packing Optimization

Powder packing in metal powders is an important aspect of additive manufacturing (oth-erwise known as 3-D printing), as it directly impacts the physical and mechanical properties of ma-terials. Improving the packing density of powder directly impacts the microstructure of the finished 3D-printed part and ultimately enhances the surface finish. To obtain the most efficient packing of a given powder, different powder blends of that material must be mixed to minimize the number of voids, irrespective of the irregularities in the particle morphology and flowability, thereby in-creasing the density of the powder. To achieve this, a methodology for mixing powder must be developed, for each powder type, to obtain the maximum packing density. This paper presents a model that adequately predicts the volumetric fraction of the powder grades necessary for obtaining the maximum packing density for a given powder sample. The model factors in the disparity between theoretical assumptions and the experimental outcome by introducing a volume reduction factor. We outline the model development steps in this paper, testing it with a real-world powder system.