Using adaptive slicing method and variable binder amount algorithm in binder jetting

Abstract

Purpose Binder jetting is one of the essential additive manufacturing methods because it is cost-effective, has no thermal stress problems and has a wide range of different materials. Using binder jetting technology in the industry is becoming more common recently. However, it has disadvantages compared to traditional manufacturing methods regarding speed. This study aims to increase the manufacturing speed of binder jetting. Design/methodology/approach This study used adaptive slicing to increase the manufacturing speed of binder jetting. In addition, a variable binder amount algorithm has been developed to use adaptive slicing efficiently. Quarter-spherical shaped samples were manufactured using a variable binder amount algorithm and adaptive slicing method. Findings Samples were sintered at 1250°C for 2 h with 10°C/min heating and cooling ramp. Scanning electron microscope analysis, surface roughness tests, and density calculations were done. According to the results obtained from the analyzes, similar surface quality is achieved by using 38% fewer layers than uniform slicing. Research limitations/implications More work is needed to implement adaptive slicing to binder jetting. Because the software of commercial printers is very difficult to modify, an open-source printer was used. For this reason, it can be challenging to produce perfect samples. However, a good start has been made in this area. Originality/value To the best of the authors’ knowledge, the actual use of adaptive slicing in binder jetting was applied for the first time in this study. A variable binder amount algorithm has been developed to implement adaptive slicing in binder jetting.

Effective use of adaptive slicing in binder jetting using Taguchi method and surface roughness measurement with image processing

“…The sum of the two fields shown in Figure 2 is used as error data. Details of the algorithm can be found in the articles by Wasserfall et al (2017) and Baş et al (2023). To perform slicing, the algorithm has a quality parameter Q , which varies between 0 and 1 and is determined intuitively.…”

“…VBAA is necessary for the efficient implementation of adaptive slicing (Baş et al , 2023). Because layer thicknesses vary, the same amount of binder should not be sent to each layer.…”

“…Adaptive slicing is generally used in the fused filament fabrication method (Hu et al , 2022; Avram et al , 2021; Gohari et al , 2021; Xu et al , 2018; Sikder et al , 2015; Sabourin et al , 1996). Adaptive slicing can be used in binder jetting, and for the first time in a real sense, Baş et al (2023) have used it. In addition, they developed a variable binder amount algorithm (VBAA) to use adaptive slicing efficiently.…”