Novel hybrid method to additively manufacture denser graphite structures using Binder Jetting

Abstract

This study introduces two hybrid processes integrating an additive manufacturing technique with post-processing treatments namely (i) Binder Jetting Printing (BJP) + Cold Isostatic Pressing (CIP) + cycle and (ii) BJP + cycle where cycle refers to a sequence of Impregnation—Drying—Pyrolysis. These two new processes yielded additively manufactured parts with higher density and reduced defects/porosities. As a testbed, we used these new processes to fabricate graphite structures. The samples produced by both methods were compared with each other and benchmarked to the samples produced by (a) BJP alone and (b) Traditional uniaxial pressing like compaction moulding. Various characterisation methods were used to investigate the microstructure and mechanical properties which showed that the porosity of hybrid manufactured samples reduces from 55% to a record 7%. This technological pathway is expected to create a new avalanche of industrial applications that are hitherto unexplored in the arena of hybrid additive manufacturing with BJP method.

3D Printing‐Enabled Design and Manufacturing Strategies for Batteries: A Review

“…Binder jetting in powders gives access to a broader range of materials, including polymers, ceramics, metals, and combinations, to manipulate their physical, mechanical, and chemical properties. [67][68][69]…”

Industry 4.0 and Digitalisation in Healthcare

“…One of the main outcomes of the advances in digital manufacturing is 3D printing technology, also called additive manufacturing (AM) [ 29 , 30 , 31 , 32 , 33 ]. AM enables the processing of polymers, ceramics, glass, and metallic alloys.…”

“…AM enables the processing of polymers, ceramics, glass, and metallic alloys. Using approaches such as the Design for Additive Manufacturing (DfAM) [ 94 ] and Materials Design by Additive Manufacturing (MaDe-by-AM) [ 95 ], novel materials can now be manufactured with ease, which includes tailored composition as well as structural and functionally graded materials [ 32 , 35 , 36 , 37 , 38 , 39 , 96 , 97 , 98 ]. By shape and composition complexity, the design of new porous materials and metamaterials can also be fabricated.…”

New, 3d Binder-Jetted Carbons with Minimal Periodic Surface Structures

“…In addition, BJ-printed parts exhibit good accuracy and fine detail, making it an ideal technique for pharmaceutical and biomedical manufacturing [4,5], energy applications such thick electrodes [6] or heat exchangers with, for instance, a triply periodic minimal surface (TPMS) structure [7,8]. As the use of graphite in BJ is relatively new, research has focused on optimizing the process when applied to carbon and graphite, as well as improving the mechanical properties of the printed architectures, by varying binder powders, deposition methods, heat treatments and post-processing such as polymer infiltration and pyrolysis (PIP) [9][10][11].…”