Polymeric Powders for Powder Bed Fusion: From Chemistry and Powder Characteristics to Process Parameters, Defects and Applications

Polymer powder bed fusion (PBF) is strongly influenced by powder chemistry and powder state, yet many studies discuss the materials and processing conditions in isolation. This review synthesises the literature using a powder-centred framework that connects polymer chemistry and powder production history to measurable powder descriptors, and then links these descriptors to processing windows, defect mechanisms, and application outcomes. Key descriptors include crystallinity and thermal transitions, additive packages, particle size distribution, morphology, and surface texture. Environmental sensitivities are also considered, including moisture uptake, temperature effects, and optical response. These factors are related to powder spreading, energy absorption, and melt solidification or sintering to explain how flowability, packing density, and melt dynamics govern porosity, lack of fusion, distortion, and degradation. Powder qualification is discussed together with lot-to-lot variability and lifecycle effects, including ageing, reuse, and refresh, using the indicators commonly reported in laboratory and production settings and supported by emerging in situ monitoring. Application case studies are consolidated to illustrate how powder state and process control translate into repeatable qualification targets as polymer PBF moves toward a predictable and transferable manufacturing practice.