Surface and Volume-Sensitized Polymer Powders for Diode Laser Powder Bed Fusion

• Applicant: Professor Dr.-Ing. Stephan Barcikowski
• Subject Area: Materials in Sintering Processes and Generative Manufacturing Processes
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 566369301

Understanding how the modification of commercial polymer feedstocks with near-infrared (NIR)-absorbing nanoparticles (NPs) influences the diode-laser-based powder bed fusion (PBF-LB/P) process is essential for addressing current challenges. Issues like inadequate laser absorption in unmodified polymer materials necessitate a thorough investigation into how these modifications can enhance energy transfer during printing. This project will explore the impact of NP distribution—whether on or in the surface or throughout the polymer matrix—on heat generation, heat distribution, and light scattering during PBF-LB/P. This research will be conducted through the collaborative efforts of material scientists from the University of Duisburg-Essen and the application partner, Evonik Industries. Consequently, the knowledge transfer project aims to jointly develop a comprehensive understanding of how the type, distribution, and loading of NPs can optimize the NIR-PBF-LB/P process, thereby improving the aging resistance of the powders and the quality of printed components. The project's core is a joint work program focused on the intensive mutual exchange of scientific knowledge and application-related challenges. The research will systematically study NIR-sensitizing NP-modified polymer powders, at the example of PA12, to evaluate their printability and resultant part quality. Additionally, the project seeks to develop aging-resistant PA12 through surface modification with NIR-absorbing NPs, aiming to reduce thermal and oxidative degradation and enhance long-term stability and mechanical properties.This project expands the knowledge of PBF-LB/P with diode lasers and corresponding feedstock modifications generated within the DFG SPP 2122 to surface-adsorbed, surface-encapsulated, and volume-additivated NP/PA12 feedstocks. Material-related determinants during PBF-NIR-LB/P are investigated to pave the way for new materials required for effective and efficient additive manufacturing with diode lasers.

• DFG Programme: Research Grants (Transfer Project)
• Application Partner: Evonik Operations GmbH