Real time observation of binder jetting printing process using high-speed X-ray imaging

Parab, Niranjan D.; Barnes, J.J.; Zhao, Cang; Cunningham, Ross; Fezzaa, Kamel; Rollett, Anthony D.; Sun, Tao

doi:10.1038/s41598-019-38862-7

Cited by 120 publications

(64 citation statements)

References 46 publications

(35 reference statements)

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“…The x-component of the droplet impact velocity for this case is ux = 0.127 m/s. In agreeance with the findings in [29], a significant number of ballistic particle ejections were observed. Furthermore, several tests were performed with a lower vertical impact speed (uz = 2.95 m/s) and particle ejections were still prevalent, albeit with reduced occurrences.…”

Section: Resultssupporting

confidence: 92%

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Experimental Investigation of Fluid-Particle Interaction in Binder Jet 3D Printing

Wagner¹,

Hu²,

Kilambi³

et al. 2021

Preprint

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Wide-scale adoption of binder jet 3D printing for mission-critical components in aerospace, biomedical, defense, and energy applications requires improvement in mechanical properties and performance characteristics of end-use components. Increased fidelity may be achieved with better understanding of the interfacial physics and complex fluid-particle interactions fundamental to the process. In this work, an experimental testing apparatus and procedure is developed to investigate the fluid and particle dynamics occurring upon impact of jetted binder droplets onto a powder bed. High-speed, microscopic imaging is employed to capture short time-scale phenomena such as ballistic particle ejection, capillary flow, and particle clustering. The effects of different process parameters (e.g., translational printhead velocity, jetting frequency, and impact velocity) on the dynamics of Inconel powder are studied. These experiments reveal that the fluid-particle interaction is significantly affected by a combination of printing parameters, ultimately governing the quality and performance of binder jet 3D printed components.

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Section: Resultssupporting

confidence: 92%

“…In Ref. [29], high-speed imaging of the fluid-particle interaction in BJ3DP was performed with synchrotron X-rays using the Advanced Photon Source at Argonne National Laboratory. With this approach, an X-ray beam passes completely through the powder bed and is converted to visible light on the opposite side.…”

Section: Fluid-particle Interaction In Bj3dpmentioning

confidence: 99%

Experimental Investigation of Fluid-Particle Interaction in Binder Jet 3D Printing

Wagner¹,

Hu²,

Kilambi³

et al. 2021

Preprint

View full text Add to dashboard Cite

show abstract

“…Indeed, the two reasons that lead to porosity are (i) jetting of binder on the build powder surface, where powder is removed by a ballistic effect, and (ii) viscous flow during the sintering process [48,49]. A similar behavior has been reported by Myers [50] and Parab et al [50,51] after sintering 3D printed SiO 2 parts. Myers in his work, observed the samples shrinked at least 13% in Z direction and 10% in X-Y surface when used powder of particle size 48 μm [50].…”

Section: Resultssupporting

confidence: 60%

Mechanical performance of lightweight ceramic structures via binder jetting of microspheres

et al. 2021

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Geometrically-complex and lightweight ceramic parts manufactured via 3D printing are prospective structures that seem to provide excellent thermal, wear and dielectric performance. In the present work, binder jetted parts based on synthetic lightweight ceramic hollow microspheres were manufactured and evaluated under different testing conditions in order to characterize their mechanical performance. The resulting structures were assessed in terms of quasi-static flexural and compressive strength, and density. Furthermore, microscopy analyses highlighted the composition of the final structures and fracture mechanisms. The printed system mainly consisted of aluminum silicon dioxide, fly ash and traces of metal. The samples yielded similar strength as that achieved on conventional bulk-based 3D printed ceramic structures. It was observed that the strength of the printed microspheres increased by sintering the parts to near-fusion temperatures due to viscous flow of material during sintering. The combination of the proposed process and feedstock represents an attractive manufacturing method for fabricating lightweight structures for applications like composite tooling molds, electromagnetic devices, and biomedical implants.

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“…The increase in ink viscosity reduces such phenomena [29]. The impact of the droplets on the powder bed may lead to additional inaccuracies [30]. A study with anatomic models using BJ technology reported a mean absolute error of 0.32 mm (variance of 0.054 mm) for accuracy for structures above 10 mm in size [3].…”

Section: Discussionmentioning

confidence: 99%

Evaluation of the Dimensional Accuracy of 3D-Printed Anatomical Mandibular Models Using FFF, SLA, SLS, MJ, and BJ Printing Technology

Msallem

Sharma

Cao

et al. 2020

JCM

159

110

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With the rapid progression of additive manufacturing and the emergence of new 3D printing technologies, accuracy assessment is mostly being performed on isosymmetric-shaped test bodies. However, the accuracy of anatomic models can vary. The dimensional accuracy of root mean square values in terms of trueness and precision of 50 mandibular replicas, printed with five common printing technologies, were evaluated. The highest trueness was found for the selective laser sintering printer (0.11 ± 0.016 mm), followed by a binder jetting printer (0.14 ± 0.02 mm), and a fused filament fabrication printer (0.16 ± 0.009 mm). However, highest precision was identified for the fused filament fabrication printer (0.05 ± 0.005 mm) whereas other printers had marginally lower values. Despite the statistically significance (p < 0.001), these differences can be considered clinically insignificant. These findings demonstrate that all 3D printing technologies create models with satisfactory dimensional accuracy for surgical use. Since satisfactory results in terms of accuracy can be reached with most technologies, the choice should be more strongly based on the printing materials, the intended use, and the overall budget. The simplest printing technology (fused filament fabrication) always scored high and thus is a reliable choice for most purposes. therefore apply to different fields of medicine and dentistry. With the continuous development of each individual technology, none stand out significantly from the others and so all are represented in the daily medical routine.Even though AM was introduced into medicine many years ago, the production of anatomical models often is still one of the main areas of application [3][4][5][6]. In opinion polls, surgeons still tend to regard anatomical models as advantageous for daily work [7]. For instance, anatomical models offer numerous advantages over other learning resources in understanding complex anatomical correlations [8]. The combination of optical and tactile sensitivity leads to a superior understanding and has defined the concept "touch to comprehend" [9]. A meta-analysis of 158 studies from 2005 to 2015 described further advantages such as possibilities for preoperative planning and time savings in the operating room, but emphasized that accuracy was not satisfactory in 34 studies [10]. Although most manufacturers provide the specifications in terms of accuracy, these are mostly uncertain in the final clinical application. In addition, most tests are performed on isosymmetric-shaped bodies [11], but the use of anatomical models may reveal larger dimensional errors. Measurements with skull and mandibular models revealed incorrect or completely missing anatomy [12]. Even deformations of 3D printed dental surgical guides were reported [13]. Inaccuracies in 3D printing applications can lead to inappropriate treatment that could harm the patient.Identical procedures with the same material under the same circumstances do not necessary lead to identical results. Statistical standards descr...

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Real time observation of binder jetting printing process using high-speed X-ray imaging

Cited by 120 publications

References 46 publications

Experimental Investigation of Fluid-Particle Interaction in Binder Jet 3D Printing

Experimental Investigation of Fluid-Particle Interaction in Binder Jet 3D Printing

Mechanical performance of lightweight ceramic structures via binder jetting of microspheres

Evaluation of the Dimensional Accuracy of 3D-Printed Anatomical Mandibular Models Using FFF, SLA, SLS, MJ, and BJ Printing Technology

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