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Volume 116
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From particle dynamics to process optimization: Effect of roller on powder spreading in laser beam powder bed fusion of molybdenum
Ge Yu a, Kefan Cao b, Meng Li a, Deyu Yue a, Jun Wen a, Xizhong An a *
a Key Laboratory for Ecological Metallurgy of Multimetallic Mineral of Ministry of Education, School of Metallurgy, Northeastern University, Shenyang, 110819, China
b The 13th Research Institute of China Electronics Technology Group Corporation, Shijiazhuang, 050051, China
10.1016/j.partic.2026.06.025
Volume 116, September 2026, Pages 214-226
Received 8 May 2026, Revised 23 June 2026, Accepted 24 June 2026, Available online 30 June 2026, Version of Record 6 July 2026.
E-mail: anxz@mail.neu.edu.cn
Highlights

• Coupled spreading parameters controls Mo powder bed quality in PBF-LB.

• Moderate roller rotation improves particle rearrangement via convective loops.

• High spreading parameters induces powder ejection, unstable flow, and larger pores.

• Five optimal trade-off solutions are presented based on Pareto front algorithm.

• Velocity dominates densification, and parameters interaction governs uniformity.


Abstract

The powder spreading process critically influences the quality and reliability of laser beam powder bed fusion of molybdenum. Compared with the blade spreader, the roller spreader shows its specific characteristics in improving powder bed performance. In this study, the coupled effects of spreading velocity and rotation speed of the roller on powder bed formation are systematically investigated using the discrete element method. Powder bed properties are evaluated in terms of packing density, uniformity, surface roughness, and pore structure. The results reveal that powder bed characteristics are governed by the interaction between spreading velocity and rotation speed. At low spreading velocities, moderate roller rotation enhances particle rearrangement through convective motion, leading to improved packing density and uniformity. Mechanism analysis shows that roller rotation alters particle transport from translational motion to vortical flow, while the evolution of contact force networks reflects a balance between force disruption and transmission. A multi-objective optimization framework based on Pareto analysis identifies optimal parameter regimes that balance deposition efficiency and powder bed quality. Statistical analysis further quantitatively confirms that spreading velocity dominates densification, whereas the interaction of spreading velocity and rotation speed plays a critical role in governing uniformity.

Graphical abstract
Keywords
DEM simulation; Roller-based powder spreading; Mechanism analysis; Pareto front algorithm; Statistical analysis
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