Skip to main content
SpringerLink
Log in

Location dependency of green density and dimension variation in binder jetted parts

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Binder jetting is a powder bed additive manufacturing process where an object is created by depositing liquid binder onto the surface of powder, selectively binding particles in each layer. The quality of the as-printed parts is influenced not only by process parameters such as layer thickness, binder saturation, print speed, and drying time but also by the location within the build box. This study highlights the location-dependent nature of green density and dimensional accuracy in the as-printed samples, and the observed trends are thoroughly discussed. A conventional powder spreading using a single roller was compared with a double roller to maximize powder packing and bed uniformity prior to binder jetting process. The significance of these observations lies in their impact on densification behavior, shrinkage, and the final geometry of the printed part.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4

Similar content being viewed by others

Data availability

Data might be available upon request.

References

  1. Mostafaei A, Elliott AM, Barnes JE, Cramer CL, Nandwana P, Chmielus M (2021) Binder jet 3D printing - process parameters, materials, properties, modeling, and challenges. Prog Mater Sci 119:100707

    Article  Google Scholar 

  2. Mostafaei A, De Vecchis PR, Buckenmeyer MJ, Wasule SR, Brown BN, Chmielus M (2019) Microstructural evolution and resulting properties of differently sintered and heat-treated binder jet 3D printed Stellite 6. Mater Sci Eng C 102:276–288

    Article  Google Scholar 

  3. Mostafaei A, Rodriguez De Vecchis P, Stevens EL, Chmielus M (2018) Sintering regimes and resulting microstructure and properties of binder jet 3D printed Ni-Mn-Ga magnetic shape memory alloys. Acta Mater 154:355–364

    Article  Google Scholar 

  4. Nandwana P, Kannan R, Siddel D (2020) Microstructure evolution during binder jet additive manufacturing of H13 tool steel. Addit Manuf 36:101534

    Google Scholar 

  5. Kannan R, Nandwana P (2021) Predicting sintering window during supersolidus liquid phase sintering of steels using feedstock analysis and CALPHAD. Mater Lett 304:130648

    Article  Google Scholar 

  6. Snow Z, Martukanitz R, Joshi S (2019) On the development of powder spreadability metrics and feedstock requirements for powder bed fusion additive manufacturing. Addit Manuf 28:78–86

    Google Scholar 

  7. Parab ND, Barnes JE, Zhao C, Cunningham RW, Rollett AD, Sun T (2019) Real time observation of binder jetting printing process using high-speed X-ray imaging. Sci Rep 9:2499

    Article  Google Scholar 

  8. Jiang R, Monteil L, Kimes K, Mostafaei A, Chmielus M (2021) Influence of powder type and binder saturation on binder jet 3D–printed and sintered Inconel 625 samples. Int J Adv Manuf Technol 116:3827–3838

    Article  Google Scholar 

  9. Mostafaei A, Rodriguez De Vecchis P, Nettleship I, Chmielus M (2019) Effect of powder size distribution on densification and microstructural evolution of binder-jet 3D-printed alloy 625. Mater Des 162:375–383

    Article  Google Scholar 

  10. Barui S, Ding H, Wang Z, Zhao H, Marathe S, Mirihanage W, Basu B, Derby B (2020) probing ink-powder interactions during 3d binder jet printing using time-resolved x-ray imaging. ACS Appl Mater Interfaces 12:34254–34264

    Article  Google Scholar 

  11. Miyanaji H, Momenzadeh N, Yang L (2018) Effect of printing speed on quality of printed parts in Binder Jetting Process. Addit Manuf 20:1–10

    Google Scholar 

  12. Ziaee M, Crane NB (2019) Binder jetting: a review of process, materials, and methods. Addit Manuf 28:781–801

    Google Scholar 

  13. K. Myers, A Paterson, T Iizuka, A Klein, (2019) The effect of print speed on surface roughness and density uniformity of parts produced using binder jet 3D printing, Solid Free. Fabr.2019 Proc. 30th Annu. Int. 122–133

  14. Oropeza D, Penny R W, Gilbert D, Hart A J (2022) Mechanized spreading of ceramic powder layers for additive manufacturing characterized by transmission x-ray imaging: Influence of powder feedstock and spreading parameters on powder layer density. Powder Technol 398:117053

  15. Rishmawi I, Salarian M, Vlasea M (2018) Tailoring green and sintered density of pure iron parts using binder jetting additive manufacturing. Addit Manuf 24:508–520

    Google Scholar 

  16. Stevens E, Schloder S, Bono E, Schmidt D, Chmielus M (2018) Density variation in binder jetting 3D-printed and sintered Ti-6Al-4V. Addit Manuf 22:746–752

    Google Scholar 

  17. Huber D, Vogel L, Fischer A (2021) The effects of sintering temperature and hold time on densification, mechanical properties and microstructural characteristics of binder jet 3D printed 17–4 PH stainless steel. Addit Manuf 46:102114

    Google Scholar 

  18. Chen Z, Chen W, Chen L, Zhu D, Chen Q, Fu Z (2022) Influence of initial relative densities on the sintering behavior and mechanical behavior of 316 L stainless steel fabricated by binder jet 3D printing. Mater Today Commun 31:103369

    Article  Google Scholar 

  19. Zago M, Lecis NFM, Vedani M, Cristofolini I (2021) Dimensional and geometrical precision of parts produced by binder jetting process as affected by the anisotropic shrinkage on sintering. Addit Manuf 43:102007

    Google Scholar 

  20. Msallem B, Neha S, Shuaishuai C, Halbeisen FS, Hans-Florian Zeilhofer FMT (2020) Evaluation of the dimensional accuracy of 3d-printed anatomical mandibular models using FFF, SLA, SLS, MJ, and BJ printing technology. J Clin Med 9:1–18

    Article  Google Scholar 

  21. Elliott AM, Nandwana P, Siddel D, Compton BG (2016) A method for measuring powder bed density in binder jet additive manufacturing process and the powder feedstock characteristics influencing the powder bed density. Solid Free Fabr Proceeding pp 1031–1037

  22. Ali U, Mahmoodkhani Y, Imani Shahabad S, Esmaeilizadeh R, Liravi F, Sheydaeian E, Huang KY, Marzbanrad E, Vlasea M, Toyserkani E (2018) On the measurement of relative powder-bed compaction density in powder-bed additive manufacturing processes. Mater Des 155:495–501

    Article  Google Scholar 

  23. Escano LI, Parab ND, Xiong L, Guo Q, Zhao C, Fezzaa K, Everhart W, Sun T, Chen L (2018) Revealing particle-scale powder spreading dynamics in powder-bed-based additive manufacturing process by high-speed X-ray imaging. Sci Rep 8:15079

    Article  Google Scholar 

  24. Inkley CG, Lawrence J, Crane NB (2023) Impact of controlled prewetting on part formation in binder jet additive manufacturing. Addit Manuf 72:103619

  25. Wu S, Yang Y, Huang Y, Han C, Chen J, Li Y, Wang D (2022) Study on powder particle behavior in powder spreading with discrete element method and its critical implications for binder jetting additive manufacturing processes. Virtual and Physical Prototyping 18:e2158877

Download references

Funding

AM would like to acknowledge the startup funding from the Department of Mechanical, Materials and Aerospace Engineering and Armour College of Engineering at Illinois Institute of Technology at Chicago, Illinois. This research was funded, in part, by the Commonwealth of Pennsylvania’s Department of Community and Economic Development (DCED), the Pennsylvania Infrastructure Technology Alliance (PITA), and the first round of the PA Manufacturing Innovation Program (PAMIP). Acknowledgments to Prof. A.D. Rollett for supporting in securing funding for this research through PITA and PAMIP. Also, Kennametal Inc. is acknowledged for providing powder for this research. Partial support from the National Science Foundation under grant number DMR-2050916 is appreciated by MD and AM.

Author information

Authors and Affiliations

  1. Department of Mechanical, Materials and Aerospace Engineering, Illinois Institute of Technology, 10 W 32nd Street, Chicago, IL, 60616, USA

    Maciej Dorula, Meisam Khademitab, Mohammad Jamalkhani & Amir Mostafaei

Authors
  1. Maciej Dorula
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Meisam Khademitab
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Mohammad Jamalkhani
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Amir Mostafaei
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

M.D.: formal analysis, investigation, visualization. M.K.: investigation, analysis. M.J.: investigation, analysis. A.M.: conceptualization, methodology, investigation, visualization, supervision, project administration, funding acquisition, writing-original draft, review and editing.

Corresponding author

Correspondence to Amir Mostafaei.

Ethics declarations

Conflicts of interest

The authors declare no competing interests.

Additional information

Publisher's Note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Dorula, M., Khademitab, M., Jamalkhani, M. et al. Location dependency of green density and dimension variation in binder jetted parts. Int J Adv Manuf Technol 132, 2853–2861 (2024). https://doi.org/10.1007/s00170-024-13529-4

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-024-13529-4

Keywords

Search

Navigation