TSS Membership Community

Dear community,

within my research group we are developing an innovative coating technology, that is based upon a new material known as the "powder sheet". The powder sheet is made out of mostly metal powder, and a small polymer %. The sheets feels on the touch like paper, they are flexible and not rigid. When placing a sheet section over a substrate area, and after laser irradiation (such as in laser cladding), the polymer degrades immediately and the metal powder in the sheets fuses to form a coating that is dense right the way and is attached to the substrate area (no need to post-process). Multiple sheets can be added to increase the coating thickness.

Some key advantages:

-Elimination of powder feeders and loose powder.

-Elimination of the need to create very flowable powder. Conventional powders and irregular powders work just as well and using a variety of PSDs.

-Easiness for multi-material possibilities, and multi-material powder blends.

-The bond between the coating and the surface material is metallurgical (hence there must be materials compatibility).

-Zero scrap. Unused sheets (or sheet parts) during processing can be recycled to make new sheets.

You can find some recent papers on this process (they are open access):

https://doi.org/10.1016/j.cirp.2022.03.012

https://doi.org/10.1080/17452759.2024.2361856

The process is still at its early stages, but we are looking specifically for industrial interest to scope for possible applications in the coatings market. The interest is welcomed in many forms, from coating development to process development to machine development.

If you would like to know more and are interested in the technology, please reach out to me via email (lupoi@tcd.ie) or LinkedIn (www.linkedin.com/in/rocco-lupoi)

Rocco Lupoi, MEng, PhD, FTCD, FIMMM

Associate Professor (additive and advanced manufacturing)

TCD Co-Director for the SFI-EPSRC Centre for Doctoral Training in Advanced Characterization of Materials

E-mail:   lupoir@tcd.ie

Office:   +353 (0) 18961729

• Personal Profile
• PI of STAM
• Funded Investigator in AMBER, the SFI Research Centre for Advanced Materials and BioEngineering Research
• Funded Investigator in I-Form, the SFI Research Centre for Advanced Manufacturing
  
  

Trinity College Dublin, The University of Dublin

Department of Mechanical, Manufacturing & Biomedical Engineering
Parsons Building
Dublin 2
Ireland

Dear community,

within my research group we are developing an innovative coating technology, that is based upon a new material known as the "powder sheet". The powder sheet is made out of mostly metal powder, and a small polymer %. The sheets feels on the touch like paper, they are flexible and not rigid. When placing a sheet section over a substrate area, and after laser irradiation (such as in laser cladding), the polymer degrades immediately and the metal powder in the sheets fuses to form a coating that is dense right the way and is attached to the substrate area (no need to post-process). Multiple sheets can be added to increase the coating thickness.

Some key advantages:

-Elimination of powder feeders and loose powder.

-Elimination of the need to create very flowable powder. Conventional powders and irregular powders work just as well and using a variety of PSDs.

-Easiness for multi-material possibilities, and multi-material powder blends.

-The bond between the coating and the surface material is metallurgical (hence there must be materials compatibility).

-Zero scrap. Unused sheets (or sheet parts) during processing can be recycled to make new sheets.

You can find some recent papers on this process (they are open access):

https://doi.org/10.1016/j.cirp.2022.03.012

https://doi.org/10.1080/17452759.2024.2361856

The process is still at its early stages, but we are looking specifically for industrial interest to scope for possible applications in the coatings market. The interest is welcomed in many forms, from coating development to process development to machine development.

If you would like to know more and are interested in the technology, please reach out to me via email (lupoi@tcd.ie) or LinkedIn (www.linkedin.com/in/rocco-lupoi)

Rocco Lupoi, MEng, PhD, FTCD, FIMMM

Associate Professor (additive and advanced manufacturing)

TCD Co-Director for the SFI-EPSRC Centre for Doctoral Training in Advanced Characterization of Materials

E-mail:   lupoir@tcd.ie

Office:   +353 (0) 18961729

• Personal Profile
• PI of STAM
• Funded Investigator in AMBER, the SFI Research Centre for Advanced Materials and BioEngineering Research
• Funded Investigator in I-Form, the SFI Research Centre for Advanced Manufacturing
  
  

Trinity College Dublin, The University of Dublin

Department of Mechanical, Manufacturing & Biomedical Engineering
Parsons Building
Dublin 2
Ireland

Dear community,

within my research group we are developing an innovative coating technology, that is based upon a new material known as the "powder sheet". The powder sheet is made out of mostly metal powder, and a small polymer %. The sheets feels on the touch like paper, they are flexible and not rigid. When placing a sheet section over a substrate area, and after laser irradiation (such as in laser cladding), the polymer degrades immediately and the metal powder in the sheets fuses to form a coating that is dense right the way and is attached to the substrate area (no need to post-process). Multiple sheets can be added to increase the coating thickness.

Some key advantages:

-Elimination of powder feeders and loose powder.

-Elimination of the need to create very flowable powder. Conventional powders and irregular powders work just as well and using a variety of PSDs.

-Easiness for multi-material possibilities, and multi-material powder blends.

-The bond between the coating and the surface material is metallurgical (hence there must be materials compatibility).

-Zero scrap. Unused sheets (or sheet parts) during processing can be recycled to make new sheets.

You can find some recent papers on this process (they are open access):

https://doi.org/10.1016/j.cirp.2022.03.012

https://doi.org/10.1080/17452759.2024.2361856

The process is still at its early stages, but we are looking specifically for industrial interest to scope for possible applications in the coatings market. The interest is welcomed in many forms, from coating development to process development to machine development.

If you would like to know more and are interested in the technology, please reach out to me via email (lupoi@tcd.ie) or LinkedIn (www.linkedin.com/in/rocco-lupoi)

Rocco Lupoi, MEng, PhD, FTCD, FIMMM

Associate Professor (additive and advanced manufacturing)

TCD Co-Director for the SFI-EPSRC Centre for Doctoral Training in Advanced Characterization of Materials

E-mail:   lupoir@tcd.ie

Office:   +353 (0) 18961729

• Personal Profile
• PI of STAM
• Funded Investigator in AMBER, the SFI Research Centre for Advanced Materials and BioEngineering Research
• Funded Investigator in I-Form, the SFI Research Centre for Advanced Manufacturing
  
  

Trinity College Dublin, The University of Dublin

Department of Mechanical, Manufacturing & Biomedical Engineering
Parsons Building
Dublin 2
Ireland