Digital Twin Approach for Powder Lifecycle Management: Investigation of Aluminum Powder Aging in L-PBF Processes

This study presents the development and implementation of a comprehensive digital twin database system for powder lifecycle management in Laser Powder Bed Fusion (L-PBF) additive manufacturing. The system architecture enables systematic documentation and analysis of powder parameters throughout multiple reuse cycles. Through application of this database system, a longitudinal investigation of aluminum powder aging was conducted, demonstrating that optimized powder reconditioning maintains component quality while maximizing resource efficiency. The digital management system establishes a foundation for data-driven powder utilization decision-making that satisfies regulatory requirements while enhancing economic efficiency.