skip to main content
OSTI.GOV title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Binder jet 3D printing – Process parameters, materials, properties, and challenges

Abstract

As a non-beam-based additive manufacturing (AM) method, binder jet 3D printing (BJ3DP) is a process where a liquid binder is jetted on layers of powdered materials, selectively joined and then followed by densification process. Among AM technologies, binder jetting holds distinctive promise due to possibility of rapid production of complex structures to achieve isotropic properties in the 3D printed samples. By taking advantage of traditional powder metallurgy, BJ3DP machines can produce prototypes in which material properties and surface finish are similar to those attained with traditional powder metallurgy. Various powdered materials have been 3D printed, however, a typical challenge during BJ3DP is developing printing and post-processing methods that maximize part performance. Therefore, a detailed review of the physical processes during 3D printing and the fundamental science of densification after sintering and post heat treatment steps are provided to understand the microstructural evolution and properties of binder jetted parts. Further, to determine the effects of the binder jetting process on metallurgical properties, the role of powder characteristics (e.g. morphology, mean size, and distribution), printing process parameters (e.g. layer thickness, print orientation, binder saturation, print speed, and drying time), sintering (e.g. temperature and holding time) and post-processing are discussed. With the developmentmore » of AM technologies and need for post-processing in 3D printed parts, it is necessary to understand the microstructural evolution during densification process and here, processing steps are explained. Finally, opportunities for future advancement are addressed.« less

Authors:
 [1]; ORCiD logo [2];  [3];  [4];  [4]; ORCiD logo [2]; ORCiD logo [2];  [5]
  1. Univ. of Pittsburgh, PA (United States); Illinois Institute of Technology, Chicago, IL (United States)
  2. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
  3. Barnes Group Advisors, Pittsburgh, PA (United States); Carnegie Mellon Univ., Pittsburgh, PA (United States)
  4. Univ. of Utah, Salt Lake City, UT (United States)
  5. Univ. of Pittsburgh, PA (United States)
Publication Date:
Research Org.:
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Sponsoring Org.:
USDOE Office of Energy Efficiency and Renewable Energy (EERE)
OSTI Identifier:
1649188
Grant/Contract Number:  
AC05-00OR22725
Resource Type:
Journal Article: Accepted Manuscript
Journal Name:
Progress in Materials Science
Additional Journal Information:
Journal Name: Progress in Materials Science; Journal ID: ISSN 0079-6425
Publisher:
Elsevier
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE

Citation Formats

Mostafaei, Amir, Elliott, Amy, Barnes, John E., Li, Fangzhou, Tan, Wenda, Cramer, Corson, Nandwana, Peeyush, and Chmielus, Markus. Binder jet 3D printing – Process parameters, materials, properties, and challenges. United States: N. p., 2020. Web. doi:10.1016/j.pmatsci.2020.100707.
Mostafaei, Amir, Elliott, Amy, Barnes, John E., Li, Fangzhou, Tan, Wenda, Cramer, Corson, Nandwana, Peeyush, & Chmielus, Markus. Binder jet 3D printing – Process parameters, materials, properties, and challenges. United States. doi:10.1016/j.pmatsci.2020.100707.
Mostafaei, Amir, Elliott, Amy, Barnes, John E., Li, Fangzhou, Tan, Wenda, Cramer, Corson, Nandwana, Peeyush, and Chmielus, Markus. Mon . "Binder jet 3D printing – Process parameters, materials, properties, and challenges". United States. doi:10.1016/j.pmatsci.2020.100707. https://www.osti.gov/servlets/purl/1649188.
@article{osti_1649188,
title = {Binder jet 3D printing – Process parameters, materials, properties, and challenges},
author = {Mostafaei, Amir and Elliott, Amy and Barnes, John E. and Li, Fangzhou and Tan, Wenda and Cramer, Corson and Nandwana, Peeyush and Chmielus, Markus},
abstractNote = {As a non-beam-based additive manufacturing (AM) method, binder jet 3D printing (BJ3DP) is a process where a liquid binder is jetted on layers of powdered materials, selectively joined and then followed by densification process. Among AM technologies, binder jetting holds distinctive promise due to possibility of rapid production of complex structures to achieve isotropic properties in the 3D printed samples. By taking advantage of traditional powder metallurgy, BJ3DP machines can produce prototypes in which material properties and surface finish are similar to those attained with traditional powder metallurgy. Various powdered materials have been 3D printed, however, a typical challenge during BJ3DP is developing printing and post-processing methods that maximize part performance. Therefore, a detailed review of the physical processes during 3D printing and the fundamental science of densification after sintering and post heat treatment steps are provided to understand the microstructural evolution and properties of binder jetted parts. Further, to determine the effects of the binder jetting process on metallurgical properties, the role of powder characteristics (e.g. morphology, mean size, and distribution), printing process parameters (e.g. layer thickness, print orientation, binder saturation, print speed, and drying time), sintering (e.g. temperature and holding time) and post-processing are discussed. With the development of AM technologies and need for post-processing in 3D printed parts, it is necessary to understand the microstructural evolution during densification process and here, processing steps are explained. Finally, opportunities for future advancement are addressed.},
doi = {10.1016/j.pmatsci.2020.100707},
journal = {Progress in Materials Science},
issn = {0079-6425},
number = ,
volume = ,
place = {United States},
year = {2020},
month = {6}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record

Save / Share: