Exploring the actual stacking height of metal powder bed in laser powder bed fusion additive manufacturing.

Pan Lu, Zhang Chen-Lin, Liu Tong, Liu Jiang-Lin, Zhang Heng-Hua, Zhang Mei

Abstract read

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Article in Scientific reports, 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Cited by 1 paper.

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1citing papers in PubMed

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1 citing paper in PubMed.

Powder Spreading Dynamics and Process Optimization at a Heterogeneous Interface for Z-Direction Multi-Material Laser Powder Bed Fusion.Materials (Basel, Switzerland) · 2026
Article

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5 · Who and what money

Authors and funding

6 authors.

Pan LuSchool of Materials Science and Engineering, Shanghai University, No.99 Shangda Road, Baoshan District, Shanghai, 200444, China.

Zhang Chen-LinSchool of Engineering Science, University of Science and Technology of China, Hefei, 230026, China.

Liu TongSchool of Materials Science and Engineering, Anhui Polytechnic University, Wuhu, 241000, China.

Liu Jiang-LinSchool of Mechanical and Transportation Engineering, Taiyuan University of Technology, Taiyuan, 030024, China.

Zhang Heng-HuaSchool of Materials Science and Engineering, Shanghai University, No.99 Shangda Road, Baoshan District, Shanghai, 200444, China. hhzhang@shu.edu.cn.

Zhang MeiSchool of Materials Science and Engineering, Shanghai University, No.99 Shangda Road, Baoshan District, Shanghai, 200444, China. zmei@shu.edu.cn.

Funding

Wuhu Metal Matrix Composite Laser Additive Manufacturing Engineering Technology Research Center KJCXPT202203

6 · The paper itself

Abstract

Laser Powder Bed Fusion (LPBF) is an additive manufacturing process that builds parts by layer-by-layer spreading and selective laser melting of metal powders. The characteristics of the powder bed are closely related to laser parameters and the particle size distribution of the metal powder. However, the actual stacking height of the powder bed changes dynamically due to shrinkage during powder spreading, melting, and solidification. This study investigates the actual stacking height of metal powders by analyzing powder flow behavior during falling, spreading, melting, and solidification using the Discrete Element Method (DEM) and Computational Fluid Dynamics (CFD). The results show that height shrinkage caused by powder spreading can be eliminated by increasing the gap between the blade and the working platform from 0 μm to 20 μm. The shrinkage rates due to solidification and liquid metal flow were found to be 8.5% and 31.5%, respectively. Furthermore, mathematical models relating the actual stacking height to layer thickness, number of layers, and solidification shrinkage were established, providing a theoretical foundation for LPBF processes with larger layer thicknesses, as well as for support structure design, printing accuracy, and allowance planning.

Indexed as

Discrete element methodLaser powder bed fusionMathematical modelMesoscopic simulation

Identifiers

PMID41565727

DOI10.1038/s41598-025-29968-2

PMCPMC12828055

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