Additive manufacturing of strong silica sand structures enabled by polyethyleneimine binder

Gilmer, Dustin B.; Han, Lu; Lehmann, Michelle L.; Siddel, Derek H.; Yang, Guang; Chowdhury, Azhad U.; Doughty, Benjamin; Elliott, Amy M.; Saito, Tomonori

doi:10.1038/s41467-021-25463-0

Title: Additive manufacturing of strong silica sand structures enabled by polyethyleneimine binder

Journal Article · 26 August 2021 · Nature Communications

DOI: https://doi.org/10.1038/s41467-021-25463-0 · OSTI ID:1902531

Gilmer, Dustin B.; Han, Lu; Lehmann, Michelle L.; Siddel, Derek H.;

; Chowdhury, Azhad U.;

;

Abstract Binder Jet Additive Manufacturing (BJAM) is a versatile AM technique that can form parts from a variety of powdered materials including metals, ceramics, and polymers. BJAM utilizes inkjet printing to selectively bind these powder particles together to form complex geometries. Adoption of BJAM has been limited due to its inability to form strong green parts using conventional binders. We report the discovery of a versatile polyethyleneimine (PEI) binder for silica sand that doubled the flexural strength of parts to 6.28 MPa compared with that of the conventional binder, making it stronger than unreinforced concrete (~4.5 MPa) in flexural loading. Furthermore, we demonstrate that PEI in the printed parts can be reacted with ethyl cyanoacrylate through a secondary infiltration, resulting in an increase in flexural strength to 52.7 MPa. The strong printed parts coupled with the ability for sacrificial washout presents potential to revolutionize AM in various applications including construction and tooling.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE; USDOE Office of Energy Efficiency and Renewable Energy (EERE); USDOE Office of Science (SC), Basic Energy Sciences (BES)

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1902531

Journal Information:: Nature Communications, Journal Name: Nature Communications Journal Issue: 1 Vol. 12; ISSN 2041-1723

Publisher:: Nature Publishing GroupCopyright Statement

Country of Publication:: United Kingdom

Language:: English

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