Powder Spreading and Layer Deposition in Metal Powder Bed Fusion

Abstract: Powder spreading and layer deposition are fundamental stages of Powder Bed Fusion (PBF) technologies and play a critical role in determining process stability and final component quality. This chapter examines the mechanisms governing powder-bed formation, highlighting the interactions between powder characteristics, process parameters, and machine architecture. Particular attention is devoted to the influence of particle size distribution, morphology, cohesion, flowability, layer thickness, recoater velocity, and environmental conditions on powder-bed quality. The resulting powder-bed is discussed as a process state variable whose characteristics, including packing density, surface coverage, effective layer thickness, and spatial homogeneity, directly affect energy absorption, melt-pool stability, defect formation, and mechanical performance. The chapter also reviews the application of the Discrete Element Method (DEM) for modelling powder spreading phenomena and quantifying powder-bed quality metrics. Finally, the role of powder reuse, lifecycle management, and future developments involving process monitoring, digital twins, and data-driven optimization strategies is discussed, emphasizing the growing importance of powder engineering in advanced metal additive manufacturing.