A review of binder jet process parameters; powder, binder, printing and sintering condition

Abstract

Binder jetting is a subset of additive manufacturing and is a suitable technique for the construction of metallic, ceramic and polymeric composite materials. In this rapid prototyping method, a binder is selectively deposited onto the powder bed, bonding these areas together to form a solid part one layer at a time usually based on a CAD model. Selection of appropriate parameters in order to obtain the final product with desired quality and proper construction time is a challenge, which is due to high influences of binder jetting process parameters on the quality of fabricated objects. Powder characteristics such as particle packing, green strength, particle size distribution, and also wettability and flow ability of powder, as well as binder characteristics and device parameters are effective factors on the binder jetting process. In this 3D printing technique, there are possible defects that are divided to two groups of before and after sintering defects that should be controlled to achieve a printed part with minimum deviation from the designed model.

Additive Manufacturing Technologies for Fabrication of Biomaterials for Surgical Procedures in Dentistry: A Narrative Review

“…The binder agent is again applied and the cycle continues until the complete printing of the object. 112 Most of the studies (64 studies) used material extrusion techniques for the scaffold manufacturing. Table 4 presents these studies, divided as follows: general commercial 3D material extrusion systems (15 studies); 8,10,14,19,[22][23][24][25][26][27]39,58,75,89,92 custom-made 3D material extrusion systems (24 studies), 9,11,12,28,33,34,41,43,45,[49][50][51]56,57,60,62,71,72,74,76 Fused deposit modeling (FDM) system is the best known commercial technique.…”

Additive Manufacturing of Micro-Electro-Mechanical Systems (MEMS)

“…The PBBJ is applicable to a large variety of materials, including polymers, metals, sand, ceramics, and mixtures of them [75][76][77][78][79][80]. The powder grains are deposited together with a liquid binding agent working as cohesive media (Figure 2d).…”

Powder-Based 3D Printing for the Fabrication of Device with Micro and Mesoscale Features

“…The PBBJ process makes use of liquid binding agent to join adjacent powder particles in each layer, after which the printing bed is lowered to allow the deposition of another powder layer as shown in Figure 2 a and Figure 3 a. This method can 3D-print a green part with a range of different materials, including polymer, metals, sand, ceramics, chalk powder, mixed materials and composites [ 61 , 63 , 76 , 83 , 89 , 90 , 91 ]. However, the post-processing (e.g., debinding) of green parts could be time-consuming, and the green parts often are not suitable for designed applications.…”

“…In this review, we will examine the capability of various powder-based 3D-printing processes in resolving micro and mesoscale features with a size ranging from 10 µm to 1 mm in size (with several examples slightly larger than one millimeter) and evaluate their suitability for various applications. At present, it is impractical to fabricate nanoscale features with powder-based 3D-printing processes [ 48 , 50 , 69 , 70 ], and the advances in macroscale powder-based 3D printing have already been extensively reviewed [ 4 , 12 , 27 , 28 , 37 , 39 , 63 , 64 , 65 , 68 , 71 , 72 , 73 , 74 , 75 , 76 , 77 , 78 , 79 ]. Therefore, these two areas are beyond the scope of this review.…”