Additive manufacturing (AM) is dynamically developing and finding applications in different industries. The quality of input material is a part of the process and of the final product quality. That is why understanding the influence of powder reuse on the properties of bulk specimens is crucial for ensuring the repeatable AM process chain. The presented study investigated the possibility of continuous reuse of AlSi7Mg0.6 powder in the laser powder bed fusion process (LPBF). To date, there is no study of AlSi7Mg0.6 powder reuse in the LPBF process to be found in the literature. This study aims to respond to this gap. The five batches of AlSi7Mg0.6 powder and five bulk LPBF samples series were characterised using different techniques. The following characteristics of powders were analysed: the powder size distribution (PSD), the morphology (scanning electron microscopy—SEM), the flowability (rotating drum analysis), and laser light absorption (spectrophotometry). Bulk samples were characterised for microstructure (SEM), chemical composition (X-ray fluorescence spectrometry—XRF), porosity (computed tomography—CT) and mechanical properties (tensile, hardness). The powder was reused in subsequent processes without adding (recycling/rejuvenation) virgin powder (collective ageing powder reuse strategy). All tested powders (powders P0–P4) and bulk samples (series S0–S3) show repeatable properties, with changes observed within error limits. Samples manufactured within the fifth reuse cycle (series S4) showed some mean value changes of measured characteristics indicating initial degradation. However, these changes also mostly fit within error limits. Therefore, the collective ageing powder reuse strategy is considered to give repeatable LPBF process results and is recommended for the AlSi7Mg0.6 alloy within at least five consecutive LPBF processes.

In this paper, polyamide 12 (PA12) blends with three types of metallic fillers are tested, which differ in the type of material and its’ morphology. Low content mixtures are taken into consideration (0.5, 1.0, 2.0, 5.0 wt%), since a low impact on mechanical properties along with obtaining antibacterial properties are desired. The investigation focuses on filler distribution as well as the influence on microstructural homogeneity of the base material after processing with polymer Laser Sintering. Moreover, the influence of the filler content on the mechanical properties and fracture behaviour were examined. Processability PA12 with bioactive metal fillers was confirmed, and no significant changes in ductile behaviour of PA 12 were observed. An in-depth analysis of the effect of the filler on microstructural homogeneity was conducted. Graphical abstract

In the era of the coronavirus pandemic, one of the most demanding areas was the supply of healthcare systems in essential Personal Protection Equipment (PPE), including face-shields and hands-free door openers. This need, impossible to fill by traditional manufacturing methods, was met by implementing of such emerging technologies as additive manufacturing (AM/3D printing). In this article, Poly(lactic acid) (PLA) filaments for Fused filament fabrication (FFF) technology in the context of the antibacterial properties of finished products were analyzed. The methodology included 2D radiography and scanning electron microscopy (SEM) analysis to determine the presence of antimicrobial additives in the material and their impact on such hospital pathogens as Staphylococcus aureus, Pseudomonas aeruginosa, and Clostridium difficile. The results show that not all tested materials displayed the expected antimicrobial properties after processing in FFF technology. The results showed that in the case of specific species of bacteria, the FFF samples, produced using the declared antibacterial materials, may even stimulate the microbial growth. The novelty of the results relies on methodological approach exceeding scope of ISO 22196 standard and is based on tests with three different species of bacteria in two types of media simulating common body fluids that can be found on frequently touched, nosocomial surfaces. The data presented in this article is of pivotal meaning taking under consideration the increasing interest in application of such products in the clinical setting.

Industrial Computed Tomography (CT) is a broadly used measurement method allowing for quality control of objects produced using additive manufacturing methods. The combination of tensile tests and simultaneous 3D imaging of the behavior of an object under a particular force (i.e. in situ examination – during the process) significantly broadens the possibilities of analyzing objects with a complex internal geometry. The purpose of this paper is to present the author’s project of a mini testing machine, to verify its functioning with regards to a static testing machine, and to present the initial in situ examination results for polymer samples.

The rapid advancement of metal additive manufacturing (AM) has driven the need for innovative feedstock materials, with nano- to micro-alloyed composite powders playing a pivotal role in the development of new materials. In aluminium alloys, alloying additives are introduced to eliminate hot cracking. Composite feedstock quality is therefore critical, as it influences the effectiveness of additives on the final part properties. The particle morphology, size distribution, and structural integrity of feedstock powders directly affect the density and mechanical performance of additively manufactured components. This study employs X-ray computed tomography (XCT) and scanning electron microscopy (SEM) for a comprehensive, quantitative evaluation of Al–Ta composite powders and their manufactured counterparts in the Laser Powder Bed Fusion (PBF-LB/M) process. The integration of XCT and SEM enables a detailed characterisation of powder features and their potential impact on microstructural integrity. Our findings demonstrate the capability of XCT as a non-destructive, high-resolution technique that complements SEM for precise volumetric analysis of powder morphology, structural homogeneity, and defect identification.