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A printability evaluation of fine and coarse powder in binder jetting of dense and porous copper parts

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Abstract

Binder jetting is a sinter-based additive manufacturing technique that integrates the layer-wise deposition in powder bed-based 3D printing with the sintering workflows of metal injection molding (MIM). For each of these powder-based processes, different feedstock characteristics such as spreadability or sinterability is required, and the powder size distribution is typically tuned to achieve the desired characteristics. However, while feedstock sizes have already been commercially standardised for MIM and powder bed fusion processes, a standard size has not been identified for binder jet. In this work, the printability of fine (D50: 14 µm) and coarse (D50: 25 µm) copper powder, representing common MIM and powder bed fusion feedstock sizes, was evaluated on a commercial binder jetting print system. Differences in particle size distribution, flowability, apparent and tapped density of the powders were characterised and correlated to deposited powder bed density, dimensional accuracy, geometrical stability, bulk density and surface topography of the green parts. Furthermore, a novel process-design solution was developed to mitigate layer-shifting print defects observed with the fine powder. The results demonstrate the flexibility of binder jet to produce green parts of varying densities as precursors to high density or high porosity sintered components. Using a layer thickness of 50 µm, a significant green part relative density above 63% was achieved using the fine powder, and a green part porosity above 55% was achieved using the coarse powder. Sintering was conducted at temperatures close to the melting point of copper; however, the formation of carbonaceous by-products prevented densification and necessitates further work before high sintered density can be achieved. Nevertheless, the coarse powder shows promising potential towards the fabrication of porous copper structures with a post-sintered relative density of 51%.

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Data availability

The datasets generated during and/or analysed during the current study are available from the corresponding author on reasonable request.

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Acknowledgements

The authors would like to thank the Advanced Remanufacturing and Technology Centre (ARTC), Agency for Science, Technology and Research (A*STAR), and the Industrial Additive Manufacturing Facility (IAMF), Agency for Science, Technology and Research (A*STAR), for their support with the research equipment and facilities.

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Authors and Affiliations

  1. Additive Manufacturing Industrialisation, Advanced Remanufacturing and Technology Centre, Agency for Science, Technology and Research, Singapore, Singapore

    Yue Hao Choong & Manickavasagam Krishnan

  2. Department of Mechanical Engineering, National University of Singapore, Singapore, Singapore

    Yue Hao Choong & Manoj Gupta

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  1. Yue Hao Choong
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  2. Manickavasagam Krishnan
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  3. Manoj Gupta
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Correspondence to Yue Hao Choong.

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Choong, Y.H., Krishnan, M. & Gupta, M. A printability evaluation of fine and coarse powder in binder jetting of dense and porous copper parts. Prog Addit Manuf 8, 1103–1125 (2023). https://doi.org/10.1007/s40964-022-00380-w

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