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Volume 110
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Khattab, D. W., Appel, O. L., Youngblood, J. P., Mort, P., & Titus, M. S. (2026). Single-handed spring actuated powder sampler for additive manufacturing. Particuology, 110, 122-130. https://doi.org/10.1016/j.partic.2026.01.007
Single-handed spring actuated powder sampler for additive manufacturing (Open Access)
Dina W. Khattab *, Owen L. Appel, Jeffrey P. Youngblood, Paul Mort, Michael S. Titus
School of Materials Engineering, Purdue University, West Lafayette, IN, 47907, USA
10.1016/j.partic.2026.01.007
Volume 110, March 2026, Pages 122-130
Received 13 November 2025, Revised 23 December 2025, Accepted 10 January 2026, Available online 20 January 2026, Version of Record 29 January 2026.
E-mail: dkhattab@purdue.edu
Highlights

• Small sampling volume, 0.5 mL.

• Single-glove operation inside AM chamber.

• Spring-actuated automatic closing system.

• Representative sampling depth starting from 10 mm below the surface.

• Sampling efficiency is dependent on powder and sampler material.


Abstract

Additive manufacturing (AM) is a rapidly expanding manufacturing technique due to its ability to produce complex-shaped parts on demand. Laser powder bed fusion (LPBF) is an additive manufacturing process that involves melting thin, ideally uniform, but not necessarily so, spread powder layers through selective laser or electron beam rastering. This process requires spreading high-quality powders, preferably those with a narrow size distribution and spherical morphology, to form a compact powder bed suitable for selective melting and the formation of high-density components. During the AM process, powder morphology and size may change due to agglomeration, partial sintering, spatter formation, and other defects; therefore, careful monitoring of these changes is essential to maintain suitable flowability and spreadability. Standard powder sampling devices, for example, as used in pharmaceutical and agricultural industries, are too large to extract AM samples without significant interlayer particle mixing. Therefore, a new compact, single-handedly actuated powder sampler was designed and fabricated for use within a selective laser melting printing chamber to sample AM powders at shallow depths. Samples can be analyzed for changes in size distribution, morphology, and composition (e.g., surface degradation) after each build.

Graphical abstract
Keywords
Additive manufacturing; Powder bed fusion; Powder sampling; Powder morphology; Probe thief
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