An experimental and numerical study of the influence of the additive manufacturing process in packing properties of particles: the printed shape matters

Investigations into the various properties of granular matter composed of particles with defined shapes have gained increasing attention. Additive manufacturing, with its freedom of shape and rapid prototyping capabilities, has significantly contributed to these studies. However, this technique may introduce defects in the manufactured particles, which can significantly affect the properties of granular materials. The extent of these defects on particles of different shapes is investigated here. Particles of various shapes (cube, octahedron, quatropod, stellated octahedron, tetrahedron, and tetrapod) were manufactured and subsequently imaged using micro-Computed Tomography. The surface roughness, solidity, and convexity of the particles were quantified. Discrete element simulations of granular bed porosity, utilizing both idealized and real particle shapes, were conducted with different surface mesh resolutions and frictional parameters. A clear influence of the manufacturing process on the packing properties of 3D printed particles was identified. This influence is not uniform across all shapes and is directly correlated with the particle convexity. For numerical simulations, a shape-dependent correction of particle density and surface characteristics are imperative for each shape under consideration, despite the fact that the particles were manufactured using the same technique and material.

Graphic abstract