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Volume 116
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CFD-DEM simulation and multi-objective optimization of a novel suction nozzle for enhanced powder delivery in selective laser melting
Xiaoping You a *, Linxue Wen a b, Junrong Wang c, Tingting Shen a, Yuxian Liang a, Qiyuan Dong a, Manqian Sun d e
a School of Mechanical and Electrical Engineering and Automation, Xiamen University Tan Kah Kee College, Zhangzhou, 363105, China
b Pen-Tung Sah Institute of Micro-Nano Science and Technology, Xiamen University, Xiamen, 361005, China
c Xiamen Han Yin Co., Ltd., Xiamen, 361000, China
d College of Marine Equipment and Mechanical Engineering, Jimei University, Xiamen, 361000, China
e Faculty of Mechanical Engineering, Lodz University of Technology, Lodz, 90-924, Poland
10.1016/j.partic.2026.06.012
Volume 116, September 2026, Pages 55-68
Received 28 April 2026, Revised 28 May 2026, Accepted 9 June 2026, Available online 16 June 2026, Version of Record 22 June 2026.
E-mail: xp.you@qq.com
Highlights

• A novel suction nozzle was developed to improve powder delivery stability in SLM.

• A validated CFD-DEM model was established to simulate gas-solid transport during suction.

• Effects of inclination angle, opening height, and opening number on performance were quantified.

• Flow-field analysis revealed the optimized nozzle enlarges the high-speed low-pressure core region.

• Multi-objective optimization achieved 47.4% higher cleaning efficiency and 34.5% faster conveying.


Abstract

The stability and efficiency of powder delivery are critical for high-quality powder deposition in selective laser melting (SLM). This study proposes a novel suction nozzle design to optimize the internal flow field at the source, breaking from the conventional focus on blades and process parameters. A validated CFD-DEM model was employed to investigate the effects of inclination angle, vertical opening height, and number of openings on cleaning efficiency and conveying speed. Flow mechanism analysis reveals that the performance improvement stems from an expanded high-speed, low-pressure core area and a more uniform flow field gradient. Orthogonal experiments and response surface analysis quantitatively identified the main effects of each parameter. Using a satisfaction function for multi-objective optimization, the optimal parameter combination (θ = 14.2°, H = 0.32H0, N = 7) was obtained, achieving a comprehensive satisfaction of 0.89. Compared to the baseline, the optimized design increases cleaning efficiency by 47.4% (to 73.98%) and conveying speed by 34.5% (to 0.74 g/s), successfully balancing both performance metrics. This work provides an effective design methodology for SLM powder delivery systems.

Graphical abstract
Keywords
Selective laser melting; Powder delivery; Suction nozzle; CFD-DEM; Flow mechanism
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