Theoretical Analysis of Self-Shrinkage Spheroidization of Irregular Degradable Polymer Powder under Thermodynamic Nonequilibrium State

Laser three-dimensional (3D) printing offers significant advantages in integrating the shape and function of regenerative tissues through biomimetic manufacturing. However, its effectiveness is limited by the lack of specialized biopolymer powders—while solvent methods that use residual solvents produce powders with poor biocompatibility, mechanical methods result in irregularly shaped crystals. In this study, a biopolymer powder spheroidization and shaping technology, which utilizes the evolution of irregular powders into spheres with minimal surface free energy in the molten state, is proposed based on the thermodynamic principle of minimum energy. Initially, the motion trajectory and temperature field of the poly(L-lactic acid) (PLLA) powder during spheroidization were quantitatively assessed and optimized using Stokes’ law and Fourier's principle. Subsequently, the cohesive forces and aggregation kinetics of the polymer chains were calculated using molecular dynamics. Finally, based on these calculations, a phase-field model was constructed to simulate the evolution of the spheroidization rate and deduce the optimal parameters for the process. This precise approach enhances PLLA spheroidization control for laser 3D printing, improves part densification and surface quality, and offers a clean and efficient path for preparing high-quality PLLA spheroidized powder for laser 3D printing.