Effect of blade geometry on the powder spreading process in additive manufacturing

In powder-bed-based additive manufacturing, the quality of the powder bed is closely related to the geometry of the blade used during the powder spreading process. In this study, the spreading process with the vertical blade, inclined blade, and round blade with different radii was performed by discrete element method to investigate the effects of blade geometry on powder spreading. The results show that at the same spreading parameters, the round blade caused the highest density than inclined blade and vertical blade. Increasing the round blade radius can improve the packing density of the powder bed, but it has little effect on the uniformity. The increase in packing density is related to the transitional smoothness of the blade surface at the entrance of the powder bed. The smoother the shape transition of the blade surface at the powder bed entrance, the powders enter the powder bed more gently, so more powders enter the powder bed, resulting in higher packing density. The results may provide suggestions for improving the laser melting process.