✔ Particle Size & Distribution
Optimal Range: 15–45 µm (for powder bed fusion, e.g., SLM, EBM).

Narrow distribution (D10-D90) ensures uniform melting and smooth layer deposition.

Finer powders (<25 µm) improve resolution but may reduce flowability.

✔ Powder Morphology (Shape & Surface)
Highly spherical particles → Better flow, packing density, and laser absorption.

Satellite-free (minimal small particles attached to larger ones).

Smooth surface reduces porosity in final parts.