Process development for green part printing using binder jetting additive manufacturing

doi:10.1007/s11465-018-0508-8

Front. Mech. Eng.

2018, Vol. 13

Issue (4) : 504-512 https://doi.org/10.1007/s11465-018-0508-8

REVIEW ARTICLE

Process development for green part printing using binder jetting additive manufacturing

Hadi MIYANAJI¹, Morgan ORTH², Junaid Muhammad AKBAR², Li YANG¹(

)

¹. Department of Industrial Engineering, University of Louisville, Louisville, KY 40292, USA
². Department of Mechanical Engineering, University of Louisville, Louisville, KY 40292, USA

Download: PDF(485 KB) HTML
Export: BibTeX | EndNote | Reference Manager | ProCite | RefWorks

Abstract

Originally developed decades ago, the binder jetting additive manufacturing (BJ-AM) process possesses various advantages compared to other additive manufacturing (AM) technologies such as broad material compatibility and technological expandability. However, the adoption of BJ-AM has been limited by the lack of knowledge with the fundamental understanding of the process principles and characteristics, as well as the relatively few systematic design guideline that are available. In this work, the process design considerations for BJ-AM in green part fabrication were discussed in detail in order to provide a comprehensive perspective of the design for additive manufacturing for the process. Various process factors, including binder saturation, in-process drying, powder spreading, powder feedstock characteristics, binder characteristics and post-process curing, could significantly affect the printing quality of the green parts such as geometrical accuracy and part integrity. For powder feedstock with low flowability, even though process parameters could be optimized to partially offset the printing feasibility issue, the qualities of the green parts will be intrinsically limited due to the existence of large internal voids that are inaccessible to the binder. In addition, during the process development, the balanced combination between the saturation level and in-process drying is of critical importance in the quality control of the green parts.

Keywords binder jetting additive manufacturing green part process optimization process development

Corresponding Author(s): Li YANG

Just Accepted Date: 26 April 2018 Online First Date: 29 May 2018 Issue Date: 31 July 2018

Cite this article:

Hadi MIYANAJI,Morgan ORTH,Junaid Muhammad AKBAR, et al. Process development for green part printing using binder jetting additive manufacturing[J]. Front. Mech. Eng., 2018, 13(4): 504-512.

URL:

https://academic.hep.com.cn/fme/EN/10.1007/s11465-018-0508-8
https://academic.hep.com.cn/fme/EN/Y2018/V13/I4/504

Fig.1 Schematics of BJ-AM process steps

Fig.2 Powder spreading defects with low-flowability powder

Fig.3 Supply-to-spread ratio for powders with different flowabilities. (a) BAG-bioglass (supply-to-spread ratio is 5); (b) alumina (supply-to-spread ratio is 3); (c) 420 SS (supply-to-spread ratio is 1)

Fig.4 Saturation level control methods. (a) Single droplet; (b) overlapping droplet; (c) overlaying droplet

Fig.5 Effect of printing speed on feature accuracy for ExOne M-Lab. (a) Slot feature; (b) experimental results; (c) dimensional accuracy

Fig.6 Nozzle clogging-induced printing defects

Fig.7 Binder permeation into the powder bed

Fig.8 In-process printing parameters

Fig.9 Common BJ-AM in-process defects from saturation-drying setting. (a) Excessive saturation, adequate drying; (b) adequate saturation, insufficient drying; (c) excessive saturation, insufficient drying; (d) insufficient binder permeation

1	Sachs E, Cima M, Cornie J, Three-dimensional printing: Rapid tooling and prototypes directly from CAD representation. CIRP Annals-Manufacturing Technology, 1990, 39(1): 201–204 https://doi.org/10.1016/S0007-8506(07)61035-X
2	Yoo J, Cima M J, Khanuja S, et al. Structural ceramic components by 3D printing. In: Proceedings of International Solid Freeform Fabrication (SFF) Symposium. Austin, 1993
3	Utela B, Anderson R L, Kuhn H. Advanced ceramic materials and processes for three-dimensional printing (3DP). In: Proceedings of International Solid Freeform Fabrication (SFF) Symposium. Austin, 2006, 290–303
4	Lanzetta M, Sachs E. Improved surface finish in 3D printing using bimodal powder distribution. Rapid Prototyping Journal, 2003, 9(3): 157–166 https://doi.org/10.1108/13552540310477463
5	Gonzalez J A, Mireles J, Lin Y, et al. Characterization of ceramic components fabricated using binder jetting additive manufacturing technology. Ceramics International, 2016, 42(9): 10559–10564 https://doi.org/10.1016/j.ceramint.2016.03.079
6	Yoo J, Cima M, Sachs E, et al. Fabrication and microstructural control of advanced ceramic components by three dimensional printing. Ceramic Engineering and Science Proceedings, 1995, 16(5): 755–762
7	Moon J, Caballero A C, Hozer L, et al. Fabrication of functionally graded reaction infiltrated SiC-Si composite by three-dimensional printing (3DP) process. Materials Science and Engineering A, 2001, 298(1–2): 110–119 https://doi.org/10.1016/S0921-5093(00)01282-X
8	Grau J, Moon J, Uhland S, et al. High green density ceramic components fabricated by the slurry-based 3DP process. In: Proceedings of International Solid Freeform Fabrication (SFF) Symposium. Austin, 1997
9	Moon J, Grau J E, Cima M J, et al. Slurry chemistry control to produce easily redispersible ceramic powder compacts. Journal of the American Ceramic Society, 2000, 83(10): 2401–2408 https://doi.org/10.1111/j.1151-2916.2000.tb01568.x
10	Bergmann C, Lindner M, Zhang W. et al. 3D printing of bone substitute implants using calcium phosphate and bioactive glasses. Journal of the European Ceramic Society, 2010, 30(12): 2563–2567 https://doi.org/10.1016/j.jeurceramsoc.2010.04.037
11	Butscher A, Bohner M, Roth C, et al. Printability of calcium phosphate powders for three-dimensional printing of tissue engineering scaffolds. Acta Biomaterialia, 2012, 8(1): 373–385 https://doi.org/10.1016/j.actbio.2011.08.027
12	Winkel A, Meszaros R, Reinsch S, et al. Sintering of 3D-printed glass/HAp composites. Journal of the American Ceramic Society, 2012, 95(11): 3387–3393 https://doi.org/10.1111/j.1551-2916.2012.05368.x
13	Ott A, Heinzl J, Janitza D, et al. Fabrication of bone substitute material by rapid prototyping. Virtual Modeling and Rapid Manufacturing, 2004, 133–138
14	D’Costa D J, Dimovski S D, Lin F, et al. Three-dimensional printing of layered machinable ductile carbide. In: Proceedings of International Solid Freeform Fabrication (SFF) Symposium. Austin, 2000
15	Gaytan S M, Cadena M A, Karim H, et al. Fabrication of barium titanate by binder jetting additive manufacturing technology. Ceramics International, 2015, 41(5): 6610–6619 https://doi.org/10.1016/j.ceramint.2015.01.108
16	Manogharan G, Kioko M, Linkous C. Binder jetting: A novel solid oxide fuel-cell fabrication process and evaluation. Journal of Materials, 2015, 67(3): 660–667 https://doi.org/10.1007/s11837-015-1296-9
17	Guo D. Vector drop-on-demand production of tungsten carbide-cobalt tooling inserts by three dimensional printing. Thesis for the Master’s Degree. Boston: Massachusetts Institute of Technology, 2004
18	Utela B, Storti D, Anderson R, et al. A review of process development steps for new material systems in three dimensional printing (3DP). Journal of Manufacturing Processes, 2008, 10(2): 96–104 https://doi.org/10.1016/j.jmapro.2009.03.002
19	Maleksaeedi S, Eng H, Wiria F E, et al. Property enhancement of 3D-printed alumina ceramics using vacuum infiltration. Journal of Materials Processing Technology, 2014, 214(7): 1301–1306 https://doi.org/10.1016/j.jmatprotec.2014.01.019
20	Yao D, Gomes C M, Zeng Y P, et al. Near zero shrinkage porous Al2O3 prepared via 3D-printing and reaction bonding. Materials Letters, 2015, 147: 116–118 https://doi.org/10.1016/j.matlet.2015.02.037
21	Miyanaji H, Zhang S, Lassell A, et al. Process development of porcelain ceramic material with binder jetting process for dental applications. Journal of Materials, 2016, 68(3): 831–841 https://doi.org/10.1007/s11837-015-1771-3
22	Holman R K, Uhland S A, Cima M J, et al. Surface adsorption effects in the inkjet printing of an aqueous polymer solution on a porous oxide ceramic substrate. Journal of Colloid and Interface Science, 2002, 247(2): 266–274 https://doi.org/10.1006/jcis.2001.8117
23	Uhland S, Holman R, DeBear B, et al. Three-dimensional printing, 3DP, of electronic ceramic components. In: Proceedings of International Solid Freeform Fabrication (SFF) Symposium. Austin, 1999
24	Cima M J, Oliveira M, Wang H R, et al. Slurry-based 3DP and fine ceramic components. In: Proceedings of International Solid Freeform Fabrication (SFF) Symposium. Austin, 2001
25	Dimitrov D, de Beer N. Developing capability profile for the three dimensional printing process. Research and Development (R&D) Journal of the South African Institution of Mechanical Engineering, 2006, 22: 17–25
26	Stopp S, Wolff T, Irlinger F, et al. A new method for printer calibration and contour accuracy manufacturing with 3D-print technology. Rapid Prototyping Journal, 2008, 14(3): 167–172 https://doi.org/10.1108/13552540810878030
27	Asadi-Eydivand M, Solati-Hashjin M, Farzad A, et al. Effect of technical parameters on porous structure and strength of 3D printed calcium sulfate prototypes. Robotics and Computer-integrated Manufacturing, 2016, 37: 57–67 https://doi.org/10.1016/j.rcim.2015.06.005
28	Johnston S, Anderson R, Storti D. Particle size influence upon sintered induced strains within 3DP stainless steel components. In: Proceedings of International Solid Freeform Fabrication (SFF) Symposium. Austin, 2003
29	Bai Y, Wagner G, Williams C B. Effect of bimodal powder mixture on powder packing density and sintered density in binder jetting of metals. In: Proceedings of International Solid Freeform Fabrication (SFF) Symposium. Austin, 2015
30	Bai Y, Williams C B. An exploration of binder jetting of copper. Rapid Prototyping Journal, 2015, 21(2): 177–185 https://doi.org/10.1108/RPJ-12-2014-0180
31	Zhang S, Minayaji H, Yang L, et al. An experimental study of ceramic dental porcelain materials using a 3D print (3DP) process. In: Proceedings of International Solid Freeform Fabrication (SFF) Symposium. Austin, 2014
32	Farzadi A, Waran V, Solati-Hashjin M, et al. Effect of layer printing delay on mechanical properties and dimensional accuracy of 3D printed porous prototypes in bone tissue engineering. Ceramics International, 2015, 41(7): 8320–8330 https://doi.org/10.1016/j.ceramint.2015.03.004
33	Lu K, Reynolds W T. 3DP process for fine mesh structure printing. Powder Technology, 2008, 187(1): 11–18 https://doi.org/10.1016/j.powtec.2007.12.017
34	Shanjani Y, Toyserkani E. Material spreading and compaction in powder-based solid freeform fabrication methods: Mathematical modeling. In: Proceedings of International Solid Freeform Fabrication (SFF) Symposium. Austin, 2008
35	Niino T, Sato K. Effect of powder compaction in plastic laser sintering fabrication. In: Proceedings of International Solid Freeform Fabrication (SFF) Symposium. Austin, 2009
36	Budding A, Vaneker T H J. New strategies for powder compaction in powder-based rapid prototyping techniques. Procedia CIRP, 2013, 6: 527–532 https://doi.org/10.1016/j.procir.2013.03.100
37	Haeri S, Wang Y, Ghita O, et al. Discrete element simulation and experimental study of powder spreading process in additive manufacturing. Powder Technology, 2017, 306: 45–54 https://doi.org/10.1016/j.powtec.2016.11.002
38	Rein M. Phenomena of liquid drop impact on solid and liquid surfaces. Fluid Dynamics Research, 1993, 12(2): 61–93 https://doi.org/10.1016/0169-5983(93)90106-K

[1]	Jinghua XU, Hongsheng SHENG, Shuyou ZHANG, Jianrong TAN, Jinlian DENG. Surface accuracy optimization of mechanical parts with multiple circular holes for additive manufacturing based on triangular fuzzy number[J]. Front. Mech. Eng., 2021, 16(1): 133-150.
[2]	Sheng WANG, Jun WANG, Yingjie XU, Weihong ZHANG, Jihong ZHU. Compressive behavior and energy absorption of polymeric lattice structures made by additive manufacturing[J]. Front. Mech. Eng., 2020, 15(2): 319-327.
[3]	Emmanuel TROMME, Atsushi KAWAMOTO, James K. GUEST. Topology optimization based on reduction methods with applications to multiscale design and additive manufacturing[J]. Front. Mech. Eng., 2020, 15(1): 151-165.
[4]	Xiaodong NIU, Surinder SINGH, Akhil GARG, Harpreet SINGH, Biranchi PANDA, Xiongbin PENG, Qiujuan ZHANG. Review of materials used in laser-aided additive manufacturing processes to produce metallic products[J]. Front. Mech. Eng., 2019, 14(3): 282-298.
[5]	Jikai LIU, Qian CHEN, Xuan LIANG, Albert C. TO. Manufacturing cost constrained topology optimization for additive manufacturing[J]. Front. Mech. Eng., 2019, 14(2): 213-221.
[6]	Wentao YAN, Stephen LIN, Orion L. KAFKA, Cheng YU, Zeliang LIU, Yanping LIAN, Sarah WOLFF, Jian CAO, Gregory J. WAGNER, Wing Kam LIU. Modeling process-structure-property relationships for additive manufacturing[J]. Front. Mech. Eng., 2018, 13(4): 482-492.
[7]	Omotoyosi H. FAMODIMU, Mark STANFORD, Chike F. ODUOZA, Lijuan ZHANG. Effect of process parameters on the density and porosity of laser melted AlSi10Mg/SiC metal matrix composite[J]. Front. Mech. Eng., 2018, 13(4): 520-527.
[8]	Ming CHEN, Chengdong WANG, Qinglong AN, Weiwei MING. Tool path strategy and cutting process monitoring in intelligent machining[J]. Front. Mech. Eng., 2018, 13(2): 232-242.
[9]	Kwok Siong TEH. Additive direct-write microfabrication for MEMS: A review[J]. Front. Mech. Eng., 2017, 12(4): 490-509.
[10]	Zilin HUANG,Gang WANG,Shaopeng WEI,Changhong LI,Yiming RONG. Process improvement in laser hot wire cladding for martensitic stainless steel based on the Taguchi method[J]. Front. Mech. Eng., 2016, 11(3): 242-249.
[11]	Shutian LIU,Quhao LI,Wenjiong CHEN,Liyong TONG,Gengdong CHENG. An identification method for enclosed voids restriction in manufacturability design for additive manufacturing structures[J]. Front. Mech. Eng., 2015, 10(2): 126-137.
[12]	Nannan GUO, Ming C. LEU. Additive manufacturing: technology, applications and research needs[J]. Front Mech Eng, 2013, 8(3): 215-243.

Viewed

Full text

Abstract

Cited

Shared

Discussed