Lecture 9

Material Jetting
Contents

1. Introduction – Material Jetting

2. Working Steps
3. Printing Characteristics
4. New Developments
5. Questions and Discussion
Additive Manufacturing 7 Families

Powder Bed Material Vat-Photo-

Fusion Extrusion polymerization

Material Binder Beam

Jetting Jetting Deposition

Sheet
Lamination
1 . Introduction – Material Jetting

• Here, a print head dispenses droplets of a photosensitive material ==

solidifies under ultraviolet (UV) light == building a part layer-by-layer.

• Materials == Thermoset photopolymers (acrylics) in a liquid form.

• Support == It is required. This is printed with a dissolvable material.

• Deposition technique == line-wise fashion

Material Jetting creates the part with ===
• High dimensional accuracy with a very smooth surface finish.
• Multi-material printing and
• A wide range of materials
• Visual prototypes

*To designate a different material or color to particular areas of the part, the model must
be exported as separate STL files.
2. Working Steps– Material Jetting

1. The liquid resin is heated to 30 – 60 oC to achieve optimal viscosity.

2. Then, hundreds of tiny droplets of photopolymer are jetted/deposited to the desired

locations.

3. A UV light source that is attached to the printhead cures the deposited material,
solidifying it (same as SLA) and creating the first layer of the part.

4. After the layer is complete, the build platform moves downwards one layer height and
the process repeats until the whole part is complete.
3. Printing Characteristics– Material Jetting
(a) Printer Parameters

 All process parameters are pre-set by the machine manufacturer.

 Layer Height: 16-32 micron
 Most accurate parts can be built and vert less warpage can be
seen

(b) Support structure

 always required
 printed in a secondary dissolvable material == removed using pressurized water or by
immersion in an ultrasonic bath.
 Little to no indication of support after removal == very smooth surface can be achieved.
(c) Matte vs. glossy

• Material Jetting offers the option of printing parts in either a glossy or matte setting.

Glossy
Matte

Glossy Matte
Support material is added only when it is A thin layer of support material is added
structurally required (i.e. for overhangs) around all the whole part
The cost of printing glossy is lower The cost of printing glossy is higher
Building time is lower Building time is lower
non-uniform finish and slight rounding of Accurate part
the sharp edges and corners on the top,
glossy surfaces.
Cost is lower Cost is higher
(d) Material

• Thermoset photopolymer resins – similar to SLA.

• Strength of Material Jetting:

 Multi-material Printing
 accurate visual and haptic prototypes

• Material
1. Standard
2. Flexible
3. Simulated Polypropylene
4. Simulated ABS
5. Castable
6. Transparent
7. Medical Grade
 (e) Post-Processing

1. Compulsory – Support removal

2. Surface Finish – Sanding

3. Aesthetic – Dyeing, Painting

4. Functional – Clear coat and metal coating

(f) Benefits and Limitations

Benefits: Limitations:
1. A near homogeneous part 1. Poor mechanical properties and
2. A very smooth surface are typically very brittle
3. Most dimensionally accurate 2. Most expensive methods

**Thus, parts are used for realistic, non-functional, prototypes that closely
represent end parts.
(g) Common applications

• Realistic prototypes that look like the real part

1. Full color visual prototypes

• The ability to print high detail, full color

models that accurately represent a final
part.

2. Medical models

3. Injection mold-like prototypes

• To verify injection molded designs.

• To check clearance, fit, assembly and form before investing in expensive tooling.
4. New Development– Material Jetting
(a) Nano Particle Jetting – XJet

• It utilizes a liquid containing metal nanoparticles or support nanoparticles.

• These particles are jetted onto the
build tray, in extremely thin layers.

• High temperatures inside the build

envelope cause the particles to bind
and the jetting liquid to evaporate
leaving behind metal parts.

• These prints are then sintered in a

furnace to create a fully dense part.
5. Questions and Discussion

1. What is Material Jetting?

2. What are the advantages and Disadvantages?
3. What is working Principle?
4. What are the common applications?
5. What is new development in this area?
Thank You!