Integrating Computational Modeling and Experiments for the Additive Manufacturing of Copper-Based Antibacterial Coatings on 304SS Surface

The development of antibacterial coatings is very important for reducing pathogenic microorganisms on frequently touched surfaces. This study explores the formation of copper-based antibacterial coatings on 304 stainless steel using laser powder bed fusion (L-PBF) and integrates molecular dynamics (MD) simulations to analyze the melting and coalescence processes at the nanoscale. Experimental results showed heterogeneous copper distribution in the melting pool, with Cu-rich regions reaching up to 69 at. %. SEM-EDS analysis confirmed localized phase separation due to rapid solidification and Marangoni convection. MD simulations of Cu-304SS nanoparticles demonstrated significant copper surface segregation at 1600 K, validating experimental observations. The antibacterial efficacy of the coatings was assessed against <i>Escherichia coli</i> and <i>Acinetobacter baumannii</i>. Results showed complete bacterial inactivation within 1 h of exposure. These findings provide insights into optimizing L-PBF parameters for creating durable and efficient self-disinfecting surfaces.