The utilization of powders for printing and additive manufacturing (AM) processes has been a critical aspect of advancing this technology from prototyping to established manufacturing. Metal powders, in particular, have seen significant growth in sales over the past decade, with a wide range of options available for various AM systems.
One such development is the Scalmalloy® aluminum-magnesium-scandium alloy, specifically designed for aerospace applications due to its low ‘buy-to-fly ratio.’ This ratio, which relates to the efficiency of material usage in part production, is essential for both environmental and commercial reasons.
Additionally, the presence of numerous suppliers for metal powders in the market has made the selection process increasingly challenging for manufacturers. Different manufacturing processes, such as gas atomization, water atomization, and plasma atomization, yield powders with varying characteristics and costs, making it crucial to set specifications for performance to determine the value of a particular supply.
On the other hand, polymer powders have historically outsold metal powders for AM processes, with a focus on fulfilling requirements for automotive, aerospace, and medical applications. The introduction of new materials, such as polyether ketone, has expanded the capabilities of laser sintering for polymers, offering properties comparable to metals.
Overall, the characterization of both metal and polymer powders plays a crucial role in optimizing performance across various printing systems, allowing for the rapid development of new materials and the ongoing expansion of the powder portfolio. Researchers continue to test and evaluate these materials to enhance their efficiency and applicability in additive manufacturing processes.
