Improvement of polymer properties for powder bed fusion by combining in situ PECVD nanoparticle synthesis and dry coating

Polypropylene (PP) powders are coated with silica nanoparticles in a fluidized bed to improve the flow behavior of the powders and the processability in powder bed fusion. The nanoparticles are produced in situ via dusty plasma-enhanced chemical vapor deposition (PECVD) in an atmospheric-pressure Ar/O-2 plasma jet fixed at the distributor plate of the fluidized bed. Hexamethyldisiloxane is used as a precursor of the nanoparticles. The influence of the oxygen concentration in the plasma gas and the number of treatment cycles on the chemical composition of the nanoparticles, the amount of nanoparticles deposited, and the flow properties of the coated PP powders is investigated. The chemical composition of the formed silica particles is determined by X-ray photon spectroscopy and infrared spectroscopy. The results reveal that the composition of the nanoparticles is SiOxCy, that is, the portion of organic residues introduced by the precursor can be controlled by changing the oxygen concentration in the plasma gas. The mass of nanoparticles deposited on the polymer powder's surface, as determined by inductively coupled optical emission spectroscopy, shows a linear dependence of the number of cycles and the oxygen concentration in the plasma gas. A considerable improvement of the flow behavior of the PP powders is observed after PECVD treatment.

Automated summary

Polypropylene (PP) powders are coated with silica nanoparticles using dusty plasma-enhanced chemical vapor deposition (PECVD) in a fluidized bed. The chemical composition and amount of deposited nanoparticles on the polymer powder surface can be controlled by adjusting the oxygen concentration in the plasma gas. PECVD treatment significantly improves the flow behavior of the PP powders.