Mathematical model of a mechatronic system for powder layer formation in additive manufacturing technologies

Abstract: Problem. Increasing the productivity of additive manufacturing (Binder Jetting technology) is limited by the low speed of powder layer deposition while maintaining high geometric accuracy of the products. Traditional systems often lead to defects such as shear deformations, formation of local voids, and interlayer delamination. Aim. To develop and study a mathematical model of a mechatronic system for powder layer formation that allows improving the productivity and quality of 3D printing. Methods. A comparative analysis of deposition systems (blade, rotating roller, and the proposed mechatronic module) was carried out using analytical modeling and computer simulation in Altair EDEM 2023 and MatLab Simulink software. Results. The developed mathematical models describe the dynamics of granular material flows and the dependencies of powder flow rate on the motion parameters of the actuating elements. It was established that the proposed mechatronic system allows achieving a deposition speed of 2800 mm/s with a shear value of 1.98 mm. This is 14 times faster than when using a squeegee (200 mm/s, shear 5 mm) and 3.3 times faster than when using a rotating roller (850 mm/s, shear 2.4 mm), while maintaining Class 7 dimensional accuracy according to GOST 26645-85. Conclusions. The resulting mathematical models of granular material flow dynamics can form the basis for the physics of powder layer formation and research in the field of improving the quality of printed products.