A laboratory-scale binder jet additive manufacturing testbed for process exploration and material development

Abstract

Binder jet additive manufacturing (BJAM) is capable of fabricating complex three-dimensional components from a variety of material classes. Understanding the fundamentals of BJAM, including spreading of thin layers of powder, powder-binder interactions, and post-processing is critical to develop robust process parameters for BJAM. Toward meeting these needs, this work presents the design, fabrication, and qualification of a testbed for modular, mechanized, BJAM. The testbed seeks replicate the operating conditions of commercial AM equipment and features fully programmable motion control including powder spreading using a precision roller mechanism, powder supply via a vibrating hopper, and gantry positioning of an inkjet printhead. The inkjet deposition system allows for the use of variable nozzle diameters, the exploration of novel binder compositions, and full control of jetting parameters. Validation of the accuracy and repeatability of the machine and its subsystems, as well as the fabrication of exemplary stainless steel components, are described. The precision engineered testbed can therefore enable the study of the BJAM process, exploration of novel binder compositions, and processing of custom powders to further scientific research and industrial applicability of BJAM.

Data Mining Technology for Equipment Machinery and Information Network Data Resources

“…Ardehjani et al have done a lot of research on establishing the engine baseline equation and used the least squares curve fitting algorithm to establish the baseline equation ( 4). Oropeza and Hart based on test bench test data, established a baseline equation using the cubic polynomial fitting method [5]. Lu et al made trend prediction based on the regression equation of engine exhaust temperature and other gas path parameters [6].…”

Advanced Fabrication of Mechanical Metamaterials Based on Micro/Nanoscale Technology

“…Figure a demonstrates the schematic of BJ 3D printing, including powder spreading variations and powder‐binder interactions during jetting. [ 143 ] Lu et al created 3D mesh structures fabricated using the BJ process and studied the influence of TiNiHf powder sizes on green strength and surface smoothness, [ 144 ] as shown in Figure 7b. In addition, choosing proper binder materials is essential as it ensures the success of printing mechanically superior and environmentally friendly components.…”

“…Reproduced with permission. [ 143 ] Copyright 2021, Springer Nature. b) 3D mesh structures fabricated using BJ technology.…”

“…Direct metal laser sintering (DMLS) is a technique that closely resembles SLS due to the Reproduced with permission. [143] Copyright 2021, Springer Nature. b) 3D mesh structures fabricated using BJ technology.…”

“…a)The schematic illustration of the BJ process. Reproduced with permission [143]. Copyright 2021, Springer Nature.…”