New Standards Released to Optimize 3D printing with Powders
Duisburg-Essen, Germany – A collaborative research effort has yielded groundbreaking new standards for 3D printing using powder bed fusion, poised to transform manufacturing in sectors like aerospace, medicine, and tooling. The initiative, led by the University of Duisburg-Essen, culminates six years of intensive inquiry into improving both processes and materials.
the Drive for Standardization in additive Manufacturing
Laser powder bed fusion (LPBF) is a prevalent industrial 3D printing technique where a laser precisely melts layers of metal or polymer powder to create complex, durable components. Recognizing the need for systematic betterment and standardization, the German Research Foundation (DFG) launched the priority program SPP 2122 in 2019. This program brought together over 30 research teams to explore customized powders,nanoparticle functionalization,and detailed process characterization.
Did You Know? LPBF allows for the creation of geometries previously impossible with conventional manufacturing methods, opening doors to innovative designs and optimized performance.
A Landmark Interlaboratory Study
The collaborative effort resulted in the creation of the largest open dataset of its kind. Thirty-two international laboratories participated in a complete interlaboratory study, producing and standardizing components from metallic and polymer powders-both with and without nanoparticle modifications. This allowed for a systematic comparison of how material properties, machine parameters, and process control influence outcomes.
Key Findings and Data Accessibility
The results, published in a special issue of Advanced Engineering Materials and accessible via an interlaboratory study dataset, provide a unique reference point for both scientific advancement and industrial submission. Dr.Anna Ziefuß,head of the Surface Chemistry and Laser Processing group at the UDE,emphasized the meaning of the study,stating,”The interlaboratory study is a milestone for science and industry,as it provides the first globally comparable data on highly complex manufacturing processes across different material classes.”
The study’s findings offer insights into the entire process chain, from initial material design and particle properties to the performance of the final component. This comprehensive understanding will facilitate the development of reliable standards, targeted process optimization, and the faster adoption of new materials.
Pro Tip: Understanding the interplay between powder characteristics and laser parameters is crucial for achieving optimal results in LPBF.
Data Release and Future Implications
the data from the interlaboratory study will be publicly available starting November 11,2025. Researchers anticipate this open access resource will accelerate innovation and collaboration within the 3D printing community. Dr. Ziefuß added, “Our goal was to present both fundamental understanding and practical solutions-and both completely open access.”
| Program | timeline | key Outcome |
|---|---|---|
| DFG SPP 2122 | 2019 – 2025 | Development of new standards for 3D printing with powders. |
| Interlaboratory Study | 2023 – 2025 | Creation of the largest open dataset for LPBF process analysis. |
| Data Release | November 11, 2025 | Public availability of the interlaboratory study dataset. |
What challenges remain in scaling up these new standards for widespread industrial adoption? and how will this research impact the cost-effectiveness of 3D printed components?
More information:
Ihsan Murat kuşoğlu et al, Large‐Scale Interlaboratory Study Along the Entire Process Chain of Laser Powder Bed Fusion: Bridging Variability, Standards, and Optimization across Metals and Polymers, Advanced Engineering Materials (2025). DOI: 10.1002/ADEM.202402930
Ihsan Kuşoğlu et al, Booklet for Standard Operational Procedures of DFG SPP2122 Interlaboratory Study measuring the effect of nanoparticles on the entire PBF-LB process chain of AlSi10Mg and PA12, DUEPUBLICO: Duisburg-Essen Publications Online, University of Duisburg-Essen, Germany (2024). DOI: 10.17185/DUEPUBLICO/82630
Stephan Barcikowski et al, DFG SPP2122 Interlaboratory Study Dataset, DUEPUBLICO: Duisburg-Essen Publications Online, University of Duisburg-Essen, Germany (2025). DOI: 10.17185/DUEPUBLICO/82674
The Future of 3D Printing
Additive manufacturing, including LPBF, is rapidly evolving. Ongoing research focuses on expanding the range of printable materials, improving process control, and reducing production costs. The development of new alloys and polymers tailored for 3D printing is a key area of innovation. Furthermore, advancements in artificial intelligence and machine learning are being integrated into LPBF processes to optimize parameters and predict component performance.
Frequently Asked Questions about 3D Printing with Powders
- What is laser powder bed fusion? LPBF is a 3D printing technique that uses a laser to melt and fuse powder materials layer by layer.
- Why are standards important in 3D printing? Standards ensure consistency,reliability,and comparability of results across different machines and materials.
- What materials can be used in LPBF? Metals like titanium, aluminum, and stainless steel, as well as polymers like nylon and polycarbonate, are commonly used.
- How does nanoparticle functionalization improve 3D printed parts? nanoparticles can enhance mechanical properties, thermal conductivity, and other characteristics of the final component.
- Where can I access the interlaboratory study data? The data will be publicly available from November 11, 2025, through the DUEPUBLICO repository.
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