The world of advanced manufacturing is evolving rapidly, and metal powders are at the heart of this transformation. Whether it’s creating intricate aerospace components or optimizing the properties of medical implants, metal powders are key to pushing the boundaries of what additive manufacturing (AM) can achieve. At Continuum Powders, we’re committed to producing high-quality, sustainable metal powders—even from reclaimed materials—without sacrificing performance.
Below, we explore the innovations that allow us to maintain critical material properties, such as flowability, density, and particle size, even when our powders are derived from used metals.
The Importance of Quality in Metal Powders
High-quality metal powder is crucial for reliable AM processes. Properties like flowability, density, and particle size play a significant role in determining the final quality of an additively manufactured part. For instance, uneven powder flow can lead to inconsistencies in layer thickness, resulting in defects or reduced mechanical performance. Similarly, particle size directly affects packing density, surface finish, and even the strength of the final part. Ensuring that these critical properties are consistent across batches is a challenge—one that Continuum Powders has tackled head-on through innovative approaches.
Particle Size: Why It Matters
Particle size is one of the most important characteristics of metal powder for AM. It impacts everything from how the powder flows during printing to the final density of the printed part. At Continuum Powders, we focus on achieving the ideal particle size distribution for various additive manufacturing methods.
- Small Particles (<20 microns): Powders with smaller particle sizes are often sought after for detailed prints with excellent surface finish. However, smaller particles can present challenges, such as reduced flowability and increased risk of agglomeration, making it crucial to maintain a balance between quality and practicality.
- Medium Particles (20-50 microns): This range is ideal for many AM processes, such as laser powder bed fusion (LPBF), where balanced flowability, layer consistency, and packing density are essential. Powders in this range offer a good compromise between ease of handling and printing precision.
- Large Particles (>50 microns): Larger particles can be beneficial for processes like binder jetting, which doesn’t require as fine a resolution as LPBF. They tend to flow more easily but may result in a coarser surface finish. Therefore, understanding the specific requirements of the AM process is key to optimizing particle size.
How Continuum Powders Achieves Optimal Particle Size
To meet these varied requirements, Continuum Powders utilizes advanced particle size analysis and proprietary Melt-to-Powder (M2P) technology to achieve precise particle size distribution. Our M2P technology allows us to convert used metal alloys directly into high-quality powder with optimal particle size and shape for AM applications. By closely monitoring and controlling particle size throughout the process, we ensure that our powders are tailored for a wide range of manufacturing applications, from aerospace to medical devices.