INTRODUCTION TO RP,

SELECTIVE POWDER
BINDING (BINDER
JETTING)

Group Members
Nayan Kumar :20bsm036
Lalit Kushwaha :20bsm033
Gireesh Jangid :20bsm022
The Binder Jetting process as illustrated above | Credits: Additively Suresh Meghwal:20bsm057
Presentation Elements
Introduction to Rapid Prototyping or AM

Binder Jetting (Selective Powder Binding) 3D Printing

Mechanical design for Binder Jetting

Binder Jet 3D Printing of different materials

Computational models for Binder Jetting

Challenges in production using Binder Jetting

• RP, or 3D printing, revolutionizes manufacturing with design
freedom, less waste, and complex geometry capabilities.
• It finds applications in medical and aerospace industries.
• Compared to traditional methods, RP reduces steps and eliminates
tooling but can consume more energy.
• Fusion and non-fusion RP techniques exist, with various materials.
• Post-processing, including machining and heat treatment, may be
required.
Rapid
• Factors like technology, organization, and supply chain influence Prototyping/
AM adoption.
AM

Figure taken from post

 Pros of RP:
Cons of RP:
 Design freedom
 Few material options,
 Variety in production
 uncertain material properties,
Pros &
 Zero lead time
 machine/process variation,
Cons of RP
 No assembly required
and
 Reduced waste
 high costs limit widespread
adoption.
 Cost, energy, and CO2
emission savings potential
 Available via license: CC BY 4.0
Content may be subject to copyright.
 Powder bed fusion (PBF)
is a key metal AM
process that involves
Powder selectively melting
Bed Fusion powder layers using heat
sources like lasers or
electron beams.
 This method yield
Metal RP anisotropic properties
due to columnar grain
processes formation
 Binder jetting is an AM
method using powdered
that uses material and a binder to
create 3D shapes. Parts are
powder bed strengthened through post-
processing, like infiltration.
 binder jet AM offers more
Binder Jet uniform thermal profiles,
( Selective equiaxed grains, and
Powder isotropic material
binding) properties, making it
suitable for mainstream
manufacturing.
The Binder Jetting process as illustrated above | Credits:
Additively
 Powder
deposition

Get
Applying
completed
Binder

THE PRINTING CYCLE

model

OF BINDER JETTING
Repeat Each layer
process Printed fast

Powder
Recoating

Figure taken from post

 Pros of Binder Jet AM Cons of Binder Jet AM
 Compatible with diverse materials, Multistep process with post-processing.
room temperature printing.

 Prevents oxidation, enables powder Low initial density, distortion during

recycling. densification.

Pros & Cons

 Large build volume, high resolution, Higher surface roughness, lower of Binder Jet
no support structures. resolution.
RP
 Minimizes thermal stress for Lack of post-processing strategies.
complex geometries.

 High production rates, porosity

control via sintering.
  Originally "3D printing" or "ProMetal," binder high-density achieved after binder jetting.
jetting was renamed in 2013.

 It's received less attention compared to fusion-

based AM methods.

Current  ExOne's binder jetting research spans ceramics,

metals, and stainless steel.
Application  Growing interest due to improved accuracy in
of Binder sintering complex structures.
Food industry uses binder jetting for
Jetting  Applications include energy storage,
electronics, food tech, fuel cells, and more.
complex shapes

 Sand shell structures made for casting.

 Diverse applications include biomedical uses

and drug delivery.

Stainless steel parabolic antenna 3D

printed and infiltrated with copper
  Printing
 Curing and De-powdering
Process Overview  Sintering and/or Infiltration
 Finishing

Binder
Jet RP
 Powder Characteristics
 Binder
 Print Parameters
 Post Processing
Influential Factors
  Printing
 Curing and De-
powdering
Process  Sintering and/or
overview Infiltration
 Finishing

Binder Jetting Process:

 Create 3D model, convert to STL.
 Spread thin powder layer with roller.
 Jet liquid binder.
 Cure with heater.
 layer by layer.
 Use counter-rotating roller for
diverse powders.
 Some require post-curing for
strength.
Credits: finemetaaworking.com
Post-Printing:
 Curing at 180-200°C based on size
and binder.
 Depowdering with vacuum and
manual brushing.
 Further hand or brush cleaning.
 Densify through sintering or
infiltration.
 Burnout step at 600-700°C for
binder removal.
  Powder Characteristics
 Binder
Influential Factors  Print Parameters
 Post Processing
qPowder Characteristics
Powder characteristics strongly influence many q Powder Characteristics
aspects of the binder jetting process operations, part
requirements, and economics. (1)shape/morphology
(2)Mean size and PSD
(3)Flow (Hall flow) and spread ability
Powder morphology governs processability in binder (4)packing density
jetting. Atomization is a common method of powder
production in which the particle shape and
morphology, surface features, mean particle size, and
PSD will be affected based on the used atomization
technique. We have two type of atomization process
(a) Gas atomization – Give round and spherical powder
shape of a range of PSD. (b) Water atomization – Gives
irregular morphology. (1) shape/morphology
So, we can say that in binder jetting highly regular,
spherical particles gives most desired properties also
help us to controlling of other machine parameters .
The mean size, also known as the average particle
size, represents the average diameter of the particles
within the powdered material. It influences various
aspects of the printing process, including powder
flowability, packing density, and layer deposition.
PSD (Particle Size Distribution): PSD refers to the
distribution of particle sizes within a powdered
material. PSD provides information about how (2)
(2) Mean size
Mean size andand
PSD PSD
particles are distributed across a range of sizes. It
affects powder flow behavior, layer uniformity, and
packing density. A narrow PSD means that most
particles are of similar sizes, while a wide PSD
indicates a broader range of particle sizes.
imp - wide rage of PSD but small particle size particles
are preferable.
Powder flowability is crucial in binder jetting, affecting how powders
are distributed and layered.

Good flowability ensures consistent powder deposition, enhancing 3D (3) Flow (Hall flow)
printing quality. High flowability allows for precise, thin layer and spread ability
spreading, improving resolution, accuracy, and part density.

Key factors influencing flowability include powder morphology,

particle size, distribution, surface properties, composition, temperature,
and environmental conditions, collectively shaping the binder jetting
process.
In binder jetting 3D printing, powder packing
density is a vital factor that measures how
tightly the powder material is arranged within
the build area. This parameter plays a crucial
role in determining the quality of 3D printed
parts and the overall success of the printing (4) packing density
process.
Several factors influence particle
packing behavior,
including: - Powder Morphology, Powder Mean
Size, Particle Size Distribution (PSD): Inter-
Particle Forces Powder Surface Chemistry
qPrint parameters
q Powder Characteristics
A) Layer thickness
B) Powder spread and print speed.
C) Binder saturation
D) Drying time and Power ratio
E) Print orientation
A)Layer thickness
The layer thickness is the height of the powder bed
along the Z-axis during printing, Simply, the layer
thickness should be greater than the maximum
particle size Increasing the layer thickness may lead to
a reduction in the powder bed density. Powder size is
a factor when defining the part features and
dimensional capability as it needs to be chosen based
on the desired layer thickness to meet the part
requirements.
 In 3D printing, powder spreading speed is vital
for cost and quality. It includes recoat,
oscillator, roller, and traverse speeds,
B) Powder spread and determining overall print speed. High roller
print speed thickness traverse speed can worsen surface quality.
Method of spreading and powder
characteristics also affect surface finish. It was
shown that increasing the roller traverse speed
with a translational velocity of V R led to an
increase in the surface roughness of the
powder bed, affecting part quality.
C) Binder saturation Binder saturation is critical in 3D
printing, influenced by printhead
capacity (fixed or adjustable). It ensures
even powder beds and precise
dimensions. Incorrect levels cause
defects and weaken parts. Balancing
binder with layer thickness is key, and
optimizing saturation enhances
strength, surface, and accuracy.
During 3D printing, drying time after binder
application is crucial and depends on several factors.
Factors include binder saturation, composition, layer
thickness, powder characteristics, and heating power
control. Insufficient drying time can lead to printhead
nozzle blockage, affecting part quality and integrity. D) Drying time and
The drying power control setting influences heater power ratio
dimensional accuracy and surface finish, with low
power ratios causing disruption and high ratios
leading to deformation and longer cycle times.
Optimizing drying time enhances dimensional
accuracy and green strength. Short drying times
result in undried binder, inaccuracies, and decreased
strength.
In binder jetting , two key orientations are critical: layer
stacking orientation and part build orientation. Layer
stacking orientation affects porosity and mechanical
properties, with variations leading to significant
differences in compressive strength and porosity.
Part build orientation, aligning objects with the x, y, and
z-axes, profoundly impacts printed part properties.
Depending on orientation, issues like surface roughness (5) Print Orientation
and texture quality may arise. Choice of orientation
affects powder layer uniformity and bonding, impacting
mechanical properties. Optimizing print orientation is
vital for achieving desired part quality and performance
in binder jetting 3D printing.
Printer design consideration
A ) Accuracy and resolution - Inkjet systems offer
high accuracy and resolution, with droplets as small as a
picolitre. Binder jetting systems typically have ±5%
accuracy, accounting for densification-induced distortion.
Resolution in binder jetting depends on droplet size,
powder size, and fluid spread for print plane resolution,
while layer thickness resolution relies on particle size
and droplet penetration depth.
B) Minimum feature size

In binder jetting 3D printing, minimum feature sizes are critical for depowdering
fragile green parts because this work is done manually. Bosses should be at
least 750 µm to avoid breakage. Thin walls, typically 1 to 3 mm thick, must
consider aspect ratios and support. Microchannels can be created down to 250
µm, but efficient powder removal is crucial. Higher saturation levels reduce
dimensional accuracy and pore quality in binder jetted parts.
C) Aspect Ratio
Length per unit diameter is called aspect ratio. Aspect ratio in binder jetting
impacts part strength and orientation during printing. Long, thin parts are
feasible but may stress during depowdering, risking breakage. The "dumbbell
effect" is a concern for mass connected to thin or high aspect ratio sections.
While no strict rules exist, consulting the printing service provider is advisable
for designing long, slender parts.
 Additive manufacturing allows complex
holes and cavities, but depowdering
D) Powder removal from these features requires techniques like
holes and cavities vacuuming, gentle agitation, and part
rotation. Weighing and light checks
confirm powder removal, and CT
scanning is an option for small, high-
value parts.
E) Infiltration runner design
In processes where we fill parts with a material
(infiltration), we need a special path (called a runner or
sprue) to guide this material into the part. Without it, the
material would gather around the part and mess up its
shape. So, we add this path when designing the part, but
it's later removed after everything is filled properly.
Usually, the company doing the printing will take care of
this runner and remove it during the final steps.
 F) Features to avoid
 Sharp angles at the junction of two planes
can create knife edges, which should be
avoided in designs for binder jetting.
 These knife edges can occur when two walls
meet or in structures like triangular or
trapezoidal bosses
 To ensure durability and accuracy, it's
essential to round these edges as fine features
like knife edges may not survive the
depowdering process.
G) Surface finish.
 Print orientation effect: In binder jetting,
vertical faces tend to be around 50% rougher
than horizontal ones, potentially impacting
fatigue life due to crack initiation.
 Surface quality consideration: Careful selection
of print orientation is essential to achieve the
desired surface quality and prevent potential
issues.
 Surface finish improvement: Adding a finer
particle layer before sintering or infiltration
enhances the part's surface.
  Polymers and monomers
 Hybrid binder
 Inorganic Binders
Binders  Minerals binder
 Organic Binders
Polymer and Monomers
In binder jetting, binders can be either polymers
in a solvent or low-viscosity liquid monomers.
Polymers rely on heat to remove the solvent
and create bridges between powder particles,
while monomers form a solid scaffold through
cross-linking during curing. Post-curing is
needed for some binder systems but is not
overly complex or costly. A variety of binders
are used, such as colloidal latex,
polyethyleneimine, colloidal silica, and
polyvinyl alcohol.
Hybrid Binders :-
Hybrid binders, incorporating fine particles or
nanoparticles, address powder segregation challenges
in inkjet 3D printing. They enhance green part density
by reducing segregation issues related to powder
characteristics. Researchers are also exploring
nanoparticle suspensions in polymeric binders,
particularly in ceramic 3D printing, for improved
density and precise shrinkage control, advancing the
quality of 3D-printed components. Ex- Polymer-
Nanoparticle Hybrids, Binder-Powder Mixtures.
Inorganic binders, commonly used in binder Inorganic Binder
jetting 3D printing, include materials like
colloidal silica and metal salts. For instance,
colloidal silica is employed to bind ceramic
powders, while metal salts can be used to
print metal components. These inorganic
binders offer excellent adhesion and
compatibility with high-temperature
processing, making them valuable in various
manufacturing applications.
 Organic binders are widely utilized in 3D
printing for their versatility and ease of
use. They include materials like polyvinyl
Organic Binder
alcohol (PVA), polyethylene glycol (PEG),
and various polymers. Organic binders
offer several advantages, such as Water
Solubility, Compatibility, Controlled
Viscosity, Green State Strength.
 Mineral-based binders are used in binder
jetting 3D printing, particularly for applications
involving ceramics and minerals. Clay-Based
Binders Gypsum Binders Limestone
Binders. Minerals binder
These mineral-based binders offer benefits like
cost-effectiveness, natural abundance, and
compatibility with mineral-based powders,
making them suitable for specific 3D printing
applications.
  Nickel based superalloys
Single alloys  Magnetics shape
Memory alloys
 Magnetic materials
 Titanium based alloys
 Copper alloy
 Iron and Stainless steel
alloys
 Cobalt based alloys  Calcium phosphate
Binder Jet 3D ceramics
Printing for Ceramics
 Calcium sulphate
 Alumina
different  Light weight metal  Porcelain
materials matrix
 Tungsten based
 Ceramic composites

composites
 Stainless steel based
composites
 Tungsten carbide based
composites
Metal Matrix  Ceramic matrix
Composites composites and gradient
materials
 Nickel-based superalloys are a popular choice for 3D
printing applications due to their high strength in high
temperatures and good corrosion resistance properties
in extreme environments
Single alloys
Figure taken from research paper.

Bimodal copper powder mixtures enhance 3D printed part

quality and precision, while hot isostatic pressing (HIP) further
improves density. Using particle-free MOD ink lowers curing
temperatures and reduces printing issues, leading to better
green part strength and overall part quality.
Above: Pure copper 3D printing is desirable to many industries/Image Source: Digital Metal

Titanium alloys are favored for aerospace and biomedical

applications. Porous structures are used for bone implants.
Contamination can affect properties. Binder jetting and layer
thickness impact porosity and strength.

Figure taken from post

 Tricalcium phosphate (TCP) is a ceramic material that can be used in
biomedical applications such as implants and scaffolds. It can be
incorporated with metals such as cobalt chrome to improve their
Ceramics mechanical properties and make them more compatible with existing
bone

Tricalcium phosphate
(TCP)

Calcium sulphate used in bone tissue engineering. Binder jetting optimization improves mechanical
properties, while heat treatment can enhance strength, but high temperatures cause cytotoxicity. Poly (ε-
caprolactone) coating post-processing improves mechanical behavior and extends resorption time. Optimal
3D printing conditions: 0.1125 mm layer thickness, x-direction printing, for best compressive strength,
toughness, and Young's modulus with improved dimensional accuracy and microchannel connectivity.
figure taken from po
st

Alumina ceramic is suitable for binder jetting. It offers stability in electrical properties and mechanical
strength. Combining alumina with binder jetting can enhance its applications in various fields, including
biomedical and structural uses.

Figure taken from post

Metal Matrix
Composites
Challenges
 Producing things with binder jetting 3D printing is hard because it's tough
in to make consistent, defect-free parts with the right properties and shape.
The process has problems like parts shrinking unevenly, forming holes,
production and shifting during printing. Researchers are trying to fix these issues by
using slow heating, adding tiny particles, and testing different

using binder materials. The goal is to make 3D-printed objects that work well without
defects.

jetting
References
THANK YOU!