WP11 – Selective.Powder

Additive manufacturing (AM) processes capable of processing metals allow for the construction of highly complex components. However, these processes often require specific material properties and involve high energy expenditure, as most industrial applications use lasers or energy-deposition nozzles under a powder bed.

To reduce energy consumption and accelerate production, metal powder deposition processes capable of being sintered have been researched to achieve final products with high detail and complexity. This project aims to address existing needs for producing highly complex metallic components (such as plastic molds and glass) using metal powder deposition techniques.

Following the deposition of metallic powders into high-temperature-resistant melting pots, the powders are sintered in a melting/sintering furnace within an inert atmosphere. This process yields finished parts with controlled surface roughness and complex internal geometries.

The project’s objective is to develop, implement, and apply a selective powder deposition system designed specifically for producing metal components. This system will include a selective material deposition unit and a melting and sintering furnace capable of an inert or inert gas-purged atmosphere, using gases such as argon or nitrogen. Application tests will focus on injection molds.

Considering the materials commonly used, this project focuses on abundant materials like ceramics, basalt, and glass. Additionally, the project adopts a sustainable strategy by using silica sand powder as a base material, which has a higher sintering temperature than the primary materials used.

During the sintering process, silica remains stable and does not crystallize, allowing it to maintain its powder form while ceramic, glass, or basalt materials crystallize and sinter. This stability enables the reuse of silica powder in the production of new parts, promoting a circular economy approach.