Effect of fine powder particles on quality of binder jetting parts

Miyanaji, Hadi; Rahman, Kazi Moshiur; Ma, Dongying; Williams, Christopher

doi:10.1016/j.addma.2020.101587

Cited by 47 publications

(31 citation statements)

References 18 publications

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“…Binder jetting is not utilized for tools, instruments and parts for the medical devices category. The reason might be that parts made with binder jetting are not usually very strong compared to other methods [ 107 , 127 ]. For medical models, it is an excellent technique since it can use colors and does not need support structures and the process is fast and affordable [ 128 ].…”

Section: Discussionmentioning

confidence: 99%

Additive Manufacturing Processes in Medical Applications

2021

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Additive manufacturing (AM, 3D printing) is used in many fields and different industries. In the medical and dental field, every patient is unique and, therefore, AM has significant potential in personalized and customized solutions. This review explores what additive manufacturing processes and materials are utilized in medical and dental applications, especially focusing on processes that are less commonly used. The processes are categorized in ISO/ASTM process classes: powder bed fusion, material extrusion, VAT photopolymerization, material jetting, binder jetting, sheet lamination and directed energy deposition combined with classification of medical applications of AM. Based on the findings, it seems that directed energy deposition is utilized rarely only in implants and sheet lamination rarely for medical models or phantoms. Powder bed fusion, material extrusion and VAT photopolymerization are utilized in all categories. Material jetting is not used for implants and biomanufacturing, and binder jetting is not utilized for tools, instruments and parts for medical devices. The most common materials are thermoplastics, photopolymers and metals such as titanium alloys. If standard terminology of AM would be followed, this would allow a more systematic review of the utilization of different AM processes. Current development in binder jetting would allow more possibilities in the future.

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Section: Discussionmentioning

confidence: 99%

Additive Manufacturing Processes in Medical Applications

2021

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“…The anisotropic dimensional change in sintering, with higher dimensional change along fabrication direction than in the building plane, is confirmed by several studies on binder jetting process [30][31][32].…”

Section: Methodsmentioning

confidence: 54%

Analysis of the Flatness Form Error in Binder Jetting Process as Affected by the Inclination Angle

Zago

Lecis

Mariani

et al. 2022

Metals

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Binder jetting (BJ) has demonstrated high competitiveness among additive manufacturing processes on account of its high production rate at a low material cost. However, both the design procedure and the process for BJ have to be further developed, aiming towards the proper control of the geometrical and dimensional precision and accuracy of the final product. This paper aims to study the factors that affect the flatness form error. Five geometries were designed to obtain planes that were inclined with respect to the fabrication direction. These planes were measured by a coordinate measuring machine in both the green and sintered state, deriving the best-fitting plane and the flatness form error. The analysis of the green samples demonstrates the prevailing influence of saturation level and layer shifting on flatness form error. In the sintered parts, a dimensional change in sintering can determine shape distortion, or an increment in the surface irregularity observed in the green state. The experimental results clearly evidence the effect of both printing and sintering on the quality of the final product, which should be considered when designing parts to be produced using BJ technology.

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“…Sieving and spreading of the powder is assisted by ultrasonic vibrations induced by transducers. 75% ultrasonic intensity (UI) was used following the suggestions given by Miyanaji et al (2020), who showed that increasing the UI in the range 25-75% improves the density of green parts fabricated with fine copper powders. All the specimens were aligned on XY plane so that the Although reducing the layer thickness increases the duration of the printing process, the use of thin layers improves the surface finish of printed parts by reducing staircase effects and enhances the inter-layer bonding (i.e.…”

Section: Specimen Manufacturing Processesmentioning

confidence: 99%

Densification behaviour of pure copper processed through cold pressing and binder jetting under different atmospheres

Romano

Migliori

Mariani

et al. 2022

RPJ

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Purpose Binder jetting is a promising route to produce complex copper components for electronic/thermal applications. This paper aims to lay a framework for determining the effects of sintering parameters on the final microstructure of copper parts fabricated through binder jetting. Design/methodology/approach The knowledge gained from well-established powder metallurgy processes was leveraged to study the densification behaviour of a fine high-purity copper powder (D50 of 3.4 µm) processed via binder jetting, by performing dilatometry and microstructural characterization. The effects of sintering parameters on densification of samples obtained with a commercial water-based binder were also explored. Findings Sintering started at lower temperature in cold-pressed (∼680 °C) than in binder jetted parts (∼900 °C), because the strain energy introduced by powder compression reduces the sintering activation energy. Vacuum sintering promoted pore closure, resulting in greater and more uniform densification than sintering in argon, as argon pressure stabilizes the residual porosity. About 6.9% residual porosity was obtained with air sintering in the presence of graphite, promoting solid-state diffusion by copper oxide reduction. Originality/value This paper reports the first systematic characterization of the thermal events occurring during solid-state sintering of high-purity copper under different atmospheres. The results can be used to optimize the sintering parameters for the manufacturing of complex copper components through binder jetting.

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Effect of fine powder particles on quality of binder jetting parts

Cited by 47 publications

References 18 publications

Additive Manufacturing Processes in Medical Applications

Additive Manufacturing Processes in Medical Applications

Analysis of the Flatness Form Error in Binder Jetting Process as Affected by the Inclination Angle

Densification behaviour of pure copper processed through cold pressing and binder jetting under different atmospheres

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