Resources for additive manufacturing: Our top 2024 highlights
As it’s a new industry, additive manufacturing (AM) is also fast-changing. Throughout 2024, we’ve helped people in AM research and industry keep up with the latest analytical innovations by sharing our expert insights through blogs, application notes, customer stories, and webinars. Read on for a quick recap of our highlights from this year!
Launching the smartest way to measure particle size: Mastersizer 3000+
The Mastersizer 3000+ is designed to provide both expert and novice users with new particle sizing possibilities thanks to three intelligent features:
SOP Architect: This feature guides users through the creation of effective Standard Operating Procedures (SOPs) with clear guidance and a step-by-step process.
Size Sure: This measurement mode isolates “transient” interferences from “steady state” measurements, minimizing the impact of human error and ensuring that results are representative.
Data Quality Guidance: This feature continuously scans for potential data quality issues, flags them, and lists causes and solutions ranked from most likely to least likely.
Whether determining the properties of new AM metal powders or verifying that powder feedstocks conform to specifications, these features help users in research and industry obtain the highest-quality particle sizing data. [Find out more]
Optimizing AM processes with particle size and shape measurements
Metal powder bed fusion (metal PBF) is one of the fastest-growing AM technologies that can be used to produce complex parts and geometries from digital files.
To get a flawless part, however, the powder bed needs to be consistent across each powder layer. Measuring particle size and shape is the best way to validate this crucial parameter, and in this webinar, our experts present the best tools for the job.
They show how laser diffraction with the Mastersizer 3000+ and static image analysis with the Morphologi 4 allow operators to easily measure particle size and shape to predict and optimize process performance. [Watch the webinar]
Supporting cutting-edge AM research
Professor Yanagitani of the University of Hyogo is looking for ways to produce water-atomized powders that achieve similar particle shape, fluidity, and output quality to gas-atomized powders.
As part of this research, he uses the Morphologi 4 to measure particle shape, praising its speed and the fact that it uses very low amounts of powder. These properties make it a cost-effective solution.
For fluidity analysis, Professor Yanagitani uses the FT4 powder rheometer, which allows him to quantitatively measure the fluidity of water-atomized powders despite their smaller particle sizes.
Achieving complete control over your processes with laser diffraction
Powder metallurgy (PM) and AM processes offer unique opportunities to reduce costs and manufacture components with specific properties. Controlling powder properties related to particle size is key to further improvements.
Laser diffraction can help you control properties such as packing behavior, flowability, response to heat, and surface finish. With Insitec, these properties can be measured within the process line.
That means manufacturers can achieve complete control over milling, atomization, and sieving processes thanks to real-time measurements of their effects.
Improve your ceramics with these instruments
Particle size is crucial across many AM processes – and ceramics are no different. Malvern Panalytical offers a range of particle characterization technologies to ensure every application has an instrument that’s fit for purpose:
- The Zetasizer is a key tool to measure and control zeta potential, which can affect agglomeration and the stability of dispersions used in the forming process.
- The Mastersizer 3000+ is a popular solution for certifying raw materials and optimizing processes like milling and spray drying.
- Like the Mastersizer, Insitec is a laser diffraction instrument for particle sizing, but it can be integrated into the process line for real-time monitoring.
- The Morphologi 4 automated image analyzer allows you to rapidly and cost-effectively measure particle shape: crucial for checking the size and sphericity of spray-dried powders.
Developing the best XRF measurement strategy for your needs
Elemental composition is a critical parameter to analyze in powder feedstocks, helping detect the presence of any contaminants rapidly instead of producing sub-par AM parts.
X-ray fluorescence is a great technique for this purpose, as it’s fast, cost-effective, and easy-to-use. It also requires minimal sample preparation, so XRF instruments like Revontium™ and the Epsilon 4 benchtop spectrometer can be used at-line for greater efficiency.
In this blog, we take a closer look at the benefits of XRF for AM applications, and we share our expert insights on developing a measurement strategy adapted to your particular sample types.
Predicting powder performance – before processing
When researching new AM powders or testing powder feedstocks, wouldn’t it be easier if you could predict powder performance based on its properties, instead of having to perform multiple test runs?
The Materials Processing Institute (MPI), have developed a method that uses the Morphologi 4’s particle size and shape measurements to predict powder performance before the laser powder bed fusion process.
With this tool, operators in research and industry can save valuable time and resources in their search for optimal powders.
Looking forward: Keep up to date in 2025!
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If you have any further questions about the instruments and topics discussed in this blog, reach out to our experts.