Powder‐Based Additive Manufacturing: A Critical Review of Materials, Methods, Opportunities, and Challenges

Abstract

As a 0‐dimensional moulding material, powder particles can realise the construction of most engineering parts and can further improve the precision moulding and high‐performance manufacturing capabilities of additive manufacturing (AM). Therefore, the powder‐based additive manufacturing methods provide an outstanding practical value and development for modern manufacturing world. However, powder materials that are utilised in additive manufacturing continue to face challenges such as a lack of accessible categories, temperature restrictions, and poor performance of moulded components. Therefore, researching for new additive manufacturing materials and procedures has become one of the important and influential ways to accelerate the progress of additive manufacturing technology and also to expand its application fields. For this purpose, it is invaluable to understand and update on the current state‐of‐the‐art of powder‐based additive manufacturing technologies. Hence, this work first reviews the research background of powder‐based 3D printing in details while systematically expounding on the technologies and equipment, material types, influencing factors, existing problems and development trends of powder‐based 3D printing. In addition, the basic principles of powder‐based 3D printing were also revealed, and the formation and optimization of metal, polymer, and ceramic powders in powder‐based 3D printing equipment were explored. Throughout the last decade, powder‐based AM has gradually emerged in the fields of biomedical and aerospace, such as the construction of tissue scaffolds and the construction of aero‐engine parts, respectively. However, powder materials may have insufficient comprehensive performance due some limitations, as the control of mechanical characteristics and dimensional accuracy of powder moulded parts are still challenging during manufacturing processes. Therefore, exploring the mechanism/s of additive manufacturing of powder‐based materials, improving the mechanical properties of powder‐based AM products, and the possible directions for improving the usability of powder materials are the main focus of this paper.This article is protected by copyright. All rights reserved.

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