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This paper presents an original model of powder\udbed generation developed within the frame of an integrated\udmodelling approach for studying the interaction of physical\udmechanisms in additive layer manufacturing (ALM) of orthopaedic implants. The model is based on cellular automata (CA) approach and describes the relationship between moving particles of different sizes during deposition on a surface in three dimensions. The surface is defined by the horizontal two-dimensional CA on which particles fall and irreversibly stick to a growing deposit. The model allows for consideration of different restructuring cases when particles are allowed to rotate as often as necessary until achievement of a local minimum\udposition. Changes in the packing density of the powder\udbed have been investigated numerically depending on technological parameters, such as particle size distribution, deposition rate and sequence of powder deposition. The model has been developed with the aim of merging to the finite element (FE)-based integrated model and is applicable to a different ranges of materials including metals and also non-metals

Powder bed generation in integrated modelling of additive layer manufacturing of orthopaedic implants