Binder Jetting

2.2. Binder Jetting

Rick Lucas

The ExOne Company

North Huntingdon, Pennsylvania

2.2.1. The Process and Materials

Binder jettings, as an additive manufacturing process, is similar to traditional paper printing: The paper page is
replaced by a layer of powder particles, and the printhead ink is replaced by a liquid binder that joins the particles
together. As the printhead rasters across the layer of powder, binder droplets (Fig. 2.2.1) are precisely jetted to selected
locations that collectively form a two-dimensional (2D) slice through the three-dimensional (3D) part that is to be
produced.

Figure 2.2.1. Jets dispensing binder.

The part is built on a platform that is repeatedly lowered, one slice at a time, followed by spreading a new layer of
powder (Fig. 2.2.2) and printing the next 2D slice until the 3D part is formed. A CAD solid model represents the 3D
shape in computerized form, and is the basis for control of the printhead as it progressively forms each 2D slice.

Figure 2.2.2. Binder jetting schematic.

The printed material may consist of plastic, metal, or ceramic powders, and includes particulates such as sand,
starch, and plaster. Binder selection depends on the material to be printed, and ranges from water for starch and
plaster to polymer-based mixtures for metals and ceramics. After the 3D shape is produced, the article may be used
as-is in its bonded form, or it may be subjected to further treatments that strengthen the bonds between particles
and/or eliminate the porosity between the particles.

2.2.2. Typical Characteristics and Applications

Low-end binder jetting machines use plaster and starch build materials with water as the binder. These binders may
contain dyes, allowing for color printing. After printing, the parts are typically strengthened by infiltrating with an
epoxy. Articles produced in these materials are used for prototyping, form and fit models, architectural models, and
relief maps.

High-end binder jetting machines use metal and ceramic powders, which require complex polymer-based binder
systems. The resulting articles can be used in one of four forms: (a) as bonded; (b) lightly sintered; (c) lightly sintered
and infiltrated; (d) highly sintered. The form used is dependent on the desired product and application.

2.2.2.1. As Bonded

The resulting part consists of bonded powder whose strength is controlled by the strength of the binder. Typically
surface finishes are coarse and require coatings if a smooth surface is desired. One of the more common applications
for the bonded product is printed sand molds. Sand molds provide a cost-effective and time-reducing alternative to
traditional methods for creating prototype and low-volume castings (Fig. 2.2.3). 3D printing sand molds and cores
directly from CAD data eliminates the need for physical patterns and pattern storage, since parts can be stored
digitally. Design freedom is the largest advantage of the process. Manufacturing and composite tooling is another
good application for this product, but generally requires a surface coating after the printing.

Figure 2.2.3. 3D-printed sand mold.

2.2.2.2. Lightly Sintered

A lightly sintered metal or ceramic product would be used when porosity is acceptable or desired for the part.
Typically a lightly sintered product would have porosity of approximately 40%. Example applications include filters
and tooling for conventional manufacturing processes.

2.2.2.3. Sintered and Infiltrated

In the infiltrated form the resulting product is a composite material. The printed part is cured and then sintered and
infiltrated with another material. The infiltrant is generally used to strengthen the part. The infiltrating material can
be an epoxy, adhesive, wax, or a metal having a lower melting point than the build material. Polymers and wax
infiltrants are used commonly for investment castings. Metal infiltrants are used for more functional parts needing
high strength (Fig. 2.2.4).

Figure 2.2.4. Metallurgical bond between two stainless steel particles after light sintering.

2.2.2.4. Highly Sintered

Highly sintered or monolithic materials are very similar to conventional pressed and sintered powder metallurgy parts
and metal injection molded parts. The basic steps of press and sinter powder metallurgy include powder blending,
die compaction, and sintering, while in metal injection molding the part is formed by injecting a mixture of metal
powder and binder into a die and then sintering. In binder jetting the powder is printed instead of die compacted or
injection molded. The advantage of binder jetting is that the creation of the mold for compaction or injection
molding is not necessary. This provides a distinct cost advantage for prototyping or low-volume production runs. The
binder jetting process also overcomes the limitation in part size in conventional powder metallurgy processes,
although controlling geometry due to distortion caused by large shrinkage remains a challenge, as is true with
conventional powder injection molding. Figure 2.2.5 illustrates examples of highly sintered parts produced by binder
jetting.

Figure 2.2.5. Examples of monolithic parts in 316 stainless steel.

2.2.3. Advantages of Binder Jetting

Various methods of 3D printing have been developed in addition to binder jetting. In contrast to joining particles by
a jetted binder, these processes build parts through a melting or micro welding process using high-energy laser or
electron beams to fuse each layer together. These processes require a base plate on which the part is built for stability
throughout the build process. Such processes require significantly more material because support material must be
used for overhangs and bridge features. The build process itself is also time-intensive.

Binder jetting is unique, in that it does not involve high heat during the build process. Other additive techniques
utilize a laser or electron beam heat source that creates residual stresses in the parts. These stresses must be relieved
in a secondary post-processing operation. Additionally with binder jetting, the parts are supported by the loose
powder in the job box, thus eliminating the need for separate support structures and allowing multiple layers of parts.
Spreading speeds significantly outperform other processes. Binder jetting has the ability to print large parts and is
often more cost-effective than other additive manufacturing methods.

2.2.4. Economics

Binder jetting is best suited for low- to medium-level production quantities. In cases where parts are complex and a
large amount of machining is required, large production quantities can be economical.

In the case of bonded products such as sand molds and cores, the process is well suited for high-volume production
of over 100,000 parts annually. This is due to the fast print times of the process. Current machines can print up to
0.028 m3/h (14 ft 3/h) resulting in less than 0.625¢/cm3 (10¢/in.3) printed mold cost.

Sintered and infiltrated as well as fully sintered materials are limited to low to medium quantities due to the slower
print times. These materials require finer powders, thinner layers, and the additional post-processing. The fastest
binder jetting metal printer on the market can produce 1966 cm3/h (120 in.3/h), which is one the fastest 3D printing
technologies. The affordability of the process is demonstrated by the fact that, among all additive manufacturing
processes, most of the small, complex metal and ceramic parts sold on the consumer market today are produced by
binder jetting.

2.2.5. General Design Considerations

The major advantage of the binder jetting process is its ability to produce complex geometries (Fig. 2.2.6). Design
considerations depend on the material being printed, the printer being used, and the application.

Figure 2.2.6. Complex component produced by BJ.

Print resolution is driven primarily by powder particle size, layer thickness, and the droplet size. The powders can be
less than 10 µm (0.0004 in.) and as large as 500 µm (0.020 in.). Generally, the binder droplets are between 40 and 60 µm
(0.0016 to 0.0024 in.) in size and can be as low as 10 µm (0.0004 in.), which gives the extremely high resolution of 1200
dpi (dots per inch).

Typical part sizes can range from 0.065 cm2 (0.1 in.2) to 516 cm2 (80 in.2) in area and from 0.25 to 97 cm (0.1 to 15 in.)
in length. The larger print platforms produce parts up to 3696 l (130 ft 3) in volume.

2.2.6. Suitable Materials

Binder jetting has the largest material set of all the 3D printing technologies. Practically any material available in
powder form is suitable for binder jetting. The powders can be angular or spherical and the powder size can vary from
less than 10 µm to over 500 µm (0.0004 to 0.020 in.). Molds and tooling generally use powders above 100 µm (0.004 in.).
Infiltrated materials work well with powder above 30 µm (0.0012 in.) and highly sintered monolithic materials need to
be around 10 µm (0.0004 in.).
Common metal materials readily available in powder forms include iron, stainless steels, tungsten, nickel, Monel,
Inconel, copper, brasses, titanium, aluminum, and magnesium. Common nonmetallic materials available include
plastics, plasters, silica and ceramic sands, glasses, alumina, zirconia, silicon, and aluminum nitride powders.
Printing reactive materials does require special controlled conditions.

2.2.7. Detailed Design Considerations

2.2.7.1. Wall Thickness

The brittle nature of gypsum and plaster materials even after a coating of super glue requires extra design
considerations. A minimum 2 mm (0.080 in.) wall thickness is needed and detail features of 500 µm (0.020 in.) are
possible.

As seen in Table 2.2.1, directly printed and sintered metal and ceramic materials require increased wall thicknesses as
the part size is incremented. Wall thickness adjustments are recommended in order to ensure success of part
throughout the printing process. Detailed features of 254 µm (0.010 in.) are possible

Table 2.2.1. Recommended Minimum Wall Thicknesses

Minimum Wall Thickness Minimum Wall Thickness

Build Dimension (in.) Build Dimension (mm)
(in.) (mm)

0.125–3 0.04 minimum 3.175–76.2 1.01 minimum

3–6 0.06 minimum 76.2–152.4 1.52 minimum

6–8 0.08 minimum 152.4–203.2 2.03 minimum

8–12 0.125 minimum 203.2–305 3.175 minimum

Bonded sand and ceramic materials used for molds generally use course powders greater than 100 µm (0.004 in.) with
thick layers 200 to 500 µm (0.008 to 0.020 in.) with a part resolution of 100 µm (0.004 in.).

2.2.7.2. Uniform Wall Thickness

Sintered materials with differences in thickness lead to distortion, internal stresses, cracking, and voids and can be
avoided by using consistent wall thickness throughout. These differences can cause nonuniform shrinkage and make
it difficult to maintain dimensional and tolerance control. When it is not possible to have uniform thicknesses due to
the part restraints, a gradual transition is recommended. Thicknesses in the range of 1.3 to 6.3 mm (0.05 to 0.25 in.)
are preferred, but exceptions in both directions are possible.

The use of webs and ribs is recommended for thin wall sections. This helps the strength and limits the distortion that
could occur during sintering (Fig. 2.2.7).

Figure 2.2.7. Use of webs and ribs for thin wall sections.

2.2.7.3. Inside Edges

Sharp corners and edges should be avoided by including fillets and radii to reduce stresses at feature intersections.
Sharp intersections and wall terminations should have a fillet based upon the wall thickness. Variable radii are
acceptable as long as the wall transitions are undeviated.

2.2.7.4. Interior Holes

As a general rule, for infiltrated materials, all through holes must have a minimum diameter of about 1 mm (0.040 in.).
Holes less than this are at risk of being filled with infiltrating materials, such as loose powder, which cannot be
successfully removed. Also, it is difficult to remove the supporting media or powder from the interior through holes
that change direction because of its limited accessibility.

2.2.7.5. Part Connections

Connection points between features must have significant surface area interactions. Parts that have lower
intersection areas have a higher risk of cracking or breakage. The lower cross section can choke the flow of the
infiltrating material and lead to unbalanced infiltration.

Citation
EXPORT
LaRoux K. Gillespie: Design for Advanced Manufacturing: Technologies and Processes. Binder Jetting, Chapter
(McGraw-Hill Professional, 2017), AccessEngineering

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