Computer simulation of pressure drop in a powder bed stabilized by a gas flow for 3D printing process in a zero gravity environment

The process known as powder bed fusion exhibits a lack of stabilization in the initial layers. One approach to address this challenge involves introducing a gas flow across the particulate medium. This solution enables more targeted applications of the technique, especially in zero-gravity environments. The objective of this study is to validate a methodology that utilizes computational fluid dynamics (CFD) and the discrete element method (DEM) to apply a gas flow within a porous medium under gravity-free conditions. The validity of the proposed solution was assessed using Ergun's equation, resulting in an error of 6.65%, and the Kozeny-Carman equation, resulting in an error of 10.53%. The drag force exerted on the particles in the simulations surpassed the gravitational force (1g). Consequently, the application investigated in this study represents an effective alternative for employing 3D printing in the absence of gravitational forces.