Binder jetting additive manufacturing process fundamentals and the resultant influences on part quality.

Miyanaji, Hadi

doi:10.18297/etd/3058

Cited by 19 publications

(32 citation statements)

References 158 publications

(384 reference statements)

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“…The plots of the surface roughness found with the Keyence microscope can be seen in Figures 7 and 8. The surface roughness values are also in agreement with literature values of sintered parts with similar particle size distributions [9,13]. A topology map of the 10 pL sample printed at 0 degrees and 3 mm/sec taken with the Keyence microscope at 100x magnification can be seen in Figure 9.…”

Section: Resultssupporting

confidence: 88%

The Effect of Print Speed on Surface Roughness and Density Uniformity of Parts Produced Using Binder Jet 3D Printing

Myers¹,

Paterson²,

Iizuka³

et al. 2021

Preprint

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One of the main benefits of binder jetting is the ability to print quickly compared to other metal additive manufacturing methods. Demand for higher throughput continues to increase, but the effects of faster print speeds on part outcomes are not yet clearly understood. MIM powders are used to achieve optimal density and surface finish. Printing at slower speeds results in densities near 98% and average surface roughness values as low as 4 μm (Ra), in the as-sintered condition. In this study, spread speeds were varied in order to understand the effect of print speed on surface roughness. 316L D90 -22 μm powder was used to print with 3 different spread speeds, 2 different layer thicknesses, and 2 different printhead droplet sizes. The surface finish and density were quantified for the sintered parts that were oriented at 0, 22.5, and 45 degrees with respect to the Z- direction.

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Section: Resultssupporting

confidence: 88%

The Effect of Print Speed on Surface Roughness and Density Uniformity of Parts Produced Using Binder Jet 3D Printing

Myers¹,

Paterson²,

Iizuka³

et al. 2021

Preprint

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“…Process ends with drainage and a decreasing drawing area (DDA). This model neglects the dynamics of the drop impact but shows the interaction of a sitting drop on a powder bed 10,26,27 The capillary pressure is the driving force for spreading and infiltration can be calculated by the Young-Laplace equation:…”

Section: Powder-binder Interactionmentioning

confidence: 99%

Influence of the dispersant on the parts quality in slurry‐based binder jetting of SiC ceramics

et al. 2022

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Binder jetting is establishing more and more in the ceramic industry to produce large complex shaped parts. A parameter with a great impact on the quality of the parts is the binder-powder interaction. The use of ceramic slurries as feedstock for this process, such as in the layerwise slurry deposition-print technology, allows a great flexibility in the composition. Such slurries are typically composed of ceramic powder, water, and small amounts of various additives. The understanding of the effect of these components on the printing quality is thus essential for the feedstock development. Four models were developed regarding the impact of additives, such as dispersants on printing. These models were confirmed or rebutted by experiments performed for an SiC slurry system with two different concentrations of a dispersant and a commercial phenolic resin used as a binder. It is shown that for this system the influence of the dispersant on the curing behavior and the clogging of the pores by dispersant can be neglected. The redispersion of the dispersant after the curing of the resin has no or only a minor effect. However, the wetting behavior determined by the surface energies of the system seem to be most crucial. In case the surface energy of the slurry additive is significantly lower than the surface energy of the binder, the strength of the green parts and the printing quality will be low. This was shown by inverse gas chromatography, contact angle measurement, rheological characterization, and mechanical tests with casted samples.

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“…Through the manufacturing experiments, a total of ten rectangular prism-shaped samples (18 × 14.5 × 6 mm 3 ) were printed for the microstructural analysis and mechanical testing. We observed that the geometry of the part has no influence on the density of the green parts 30,31 . The rectangular prism shape for BJP samples were selected for further characterization.…”

Section: Methodsmentioning

confidence: 66%

“…Z d is the current building height. From ( 2 ), a direct relation between the layer thickness and the binder saturation is evident and this is the reason behind "green" body’s mechanical properties and dimensional accuracy 31 .…”

Section: Methodsmentioning

confidence: 99%

Novel hybrid method to additively manufacture denser graphite structures using Binder Jetting

Popov

Fleisher

Muller‐Kamskii

et al. 2021

Sci Rep

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This study introduces two hybrid processes integrating an additive manufacturing technique with post-processing treatments namely (i) Binder Jetting Printing (BJP) + Cold Isostatic Pressing (CIP) + cycle and (ii) BJP + cycle where cycle refers to a sequence of Impregnation—Drying—Pyrolysis. These two new processes yielded additively manufactured parts with higher density and reduced defects/porosities. As a testbed, we used these new processes to fabricate graphite structures. The samples produced by both methods were compared with each other and benchmarked to the samples produced by (a) BJP alone and (b) Traditional uniaxial pressing like compaction moulding. Various characterisation methods were used to investigate the microstructure and mechanical properties which showed that the porosity of hybrid manufactured samples reduces from 55% to a record 7%. This technological pathway is expected to create a new avalanche of industrial applications that are hitherto unexplored in the arena of hybrid additive manufacturing with BJP method.

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Binder jetting additive manufacturing process fundamentals and the resultant influences on part quality.

Cited by 19 publications

References 158 publications

The Effect of Print Speed on Surface Roughness and Density Uniformity of Parts Produced Using Binder Jet 3D Printing

The Effect of Print Speed on Surface Roughness and Density Uniformity of Parts Produced Using Binder Jet 3D Printing

Influence of the dispersant on the parts quality in slurry‐based binder jetting of SiC ceramics

Novel hybrid method to additively manufacture denser graphite structures using Binder Jetting

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