Binder Jetting

The 7 methods (from ASTM F42)

Vat photopolymerization (SLA): material is cured by light-activated

polymerization.

Material jetting (Polyjet*): droplets of build material are jetted to form an

object.

Binder jetting (3DP): liquid bonding agent is jetted to join powder

materials.

Material extrusion (FDM): material is selectively dispensed through a nozzle

and solidifies.

Sheet lamination (LOM): sheets are bonded to form an object.

Powder bed fusion (SLS/SLM/EBM): (thermal) energy is used to selectively

fuse regions of a powder bed.

Directed energy deposition (LENS): focused thermal energy is used to fuse

materials by melting as deposition occurs.
Binder jetting: original “3D printing”

• Binder jetting or 3DPTM was developed in the early 1990s at MIT by Professor
Emanuel Sachs.
• A wide range of polymer, composite, metal, and ceramic materials have been
demonstrated, but only a subset of these are commercially available.
→Utilizes ink-jet technology to apply binder to powder, deposited in layers,
and binder is cured (optionally with added ultraviolet light and/or heat).

Gibson, Ian, et al. Additive manufacturing technologies. Vol. 17.: Springer, 2021. http://web.mit.edu/tdp/www/
3D Printing
• Rapid and flexible production of prototype parts, end-use parts,
and tools directly from a CAD model
– First AM technology to achieve the fabrication of complex ceramic parts
– Pioneered the direct fabrication of ceramic molds for casting
– First functionally gradient material in ceramic pre-forms

• MIT licensed the BJ technology to more than five companies for

commercialization, according to the type of material and
application that each license was allowed to exploit.
– Soligen, Extrudehone, Specific Surface Corporation, TDK Corporation,
Therics, Z Corporation
– Affordable at $18~30K
BJ Process
• Each layer begins with a thin distribution of powder spread over the
surface of a powder bed.
• Typically, binder droplets (~80 µm in diameter) form spherical
agglomerates of binder liquid and powder particles as well as provide
bonding to the previously printed layer.
• A piston that supports the powder bed and the part-in-progress lowers so
that the next powder layer can be spread and selectively joined.
• This process is repeated until the part, or array of parts, is completed.
• Parts are self-supporting in the powder bed so that support structures are
not needed.
• The printed part is typically left in the powder-bed after its completion in
order for the binder to fully set and for the green part to gain strength.
• Post-processing involves removing the part from the powder bed,
removing unbound powder via pressurized air, and infiltrating the part with
another material to make it stronger and enhance mechanical properties.
BJ Process
→What is the difference between the powder bed fusion process and BJ?
→What is the desirable characteristic of powders? Why?
→How to make the process more scalable?
→Why it is very advantageous to fabricate ceramics by BJ?
→What are the typical applications of BJ?

Schematic illustration of the three-dimensional-printing

https://www.youtube.com/watch?v=RNNxEoXuvuw process. Source: After E. Sachs and M. Cima.
Capabilities of BJ
• Combines powders and binders
– No tooling or geometric limitations
• Overhangs, undercuts and internal volumes can be created
– As long as there is a hole for the loose powder to escape
• Form any material that can be obtained as a powder
– Flexibility in handling a wide range of materials, including ceramics, metals, polymers
and composites
• Dispense different materials by different print heads
– Locally tailor the material composition
• Control the internal microstructure of the printed part.
• Readily scaled in production rate through the use of multiple nozzle
technology.
• Some binder jetting machines contain nozzles that print color, not
binder, enabling the fabrication of parts with many colors.
Commercially available materials

• Z Corporation started with starch material and used a water-based

binder similar to a standard house-hold glue.
• 3D Systems supplies plaster based material (calcium sulfate
hemihydrate) and the binder is water-based.
• Voxeljet supplies a PMMA (poly-methyl methacrylate) powder and
uses a liquid binder that reacts at room temperature.
• Binders must deliver certain characteristics that work harmoniously
with the powder material being printed. Considerations include
viscosity, saturation, flowability, as well as debinding
characteristics.
• Unprinted powders are fully recyclable.
• The typical layer height depends on the material: for full color
models the typical layer height is 100 microns, for metal parts 50
microns, and for sand casting mold materials 200-400 microns.
Structural Ceramics
• Fabricate complex-shaped structural ceramic
components
– Spreading sub-micron powders and printing
an organic binder
– Green parts are removed
• Remove binder by thermal decomposition
• Isostatically pressed and sintered for densification
“Direct” metal tools with cooling passages

• Create tooling with integral cooling passages

– Conformable to the molding cavity and near to
its surface
– Tools with cooling passages can be used to
control the temperature accurately and yield
reproducible parts with predictable properties

Cooling passage printed conformable to

the tooling cavity
Composites and Functionally
Gradient Parts

• Locally tailor the material composition of a part

– Multiple-material printhead
– Strength, toughness, heat transfer, etc.
• Enhanced material properties
– Toughness
– Wear
– Thermal or electrical conductivity
– Thermal expansion
BJ Parts
BJ Machines: Specifications,
process capability
Machine specifications for BJ machines

Gibson, Ian, et al. Additive manufacturing technologies. Vol. 17.: Springer, 2021.
ZCorp’s 3DP
• First commercial model introduced in 1997.
• As of 2012, ZCorp was purchased by 3D Systems and their
product line was merged into the ProJet line of printers.
• Models and specifications are shown in Table 8.1.

Zprinter 450
(8X10X8 in)
https://www.youtube.com/watch?v=ps0WEZbDjHE www.zcorp.com
The Process
• A thin layer of the powder is deposited onto the build bed.
• A water-based liquid is injected into a powder bed of powder by means of an inkjet print head,
resulting in local bonding (i.e., the powder is glued together by the binder where it is printed).
• The build piston is lowered, and a new layer of powder is spread over the surface and the process
is repeated.
• Powder that is not wetted stays in the construction chamber and supports the model.
• The models must be infiltrated with wax or epoxy resin for robustness; otherwise they are not
resistant to mechanical stress.

ZCorp Z450

https://www.sculpteo.com/blog/2010/05/14/discover-the-zprinter-650-from-zcorp-in-
https://www.3dbeginners.com/zcorp-3d-printer-review/
our-head-office-near-paris-to-make-coloured-objects/
Materials & examples of ZCorp parts

A wide range of colors and materials including:

✓ High performance composite material

✓ Snap-fit material
✓ Elastomeric material
✓ Investment casting material
✓ Direct casting material

ZCorp 3D printer

ProJet 460 Plus (left), colored model (right);

(Source: ZCorp)
3D Systems
Advantages:
• Low cost printing
• Versatility
• Multiple color schemes
• Simple to operate
• Minimum wastage
Disadvantages:
• Limited strength
• Poor surface finish
Applications:
• Concept models
• Casting
• Medical models
Examples:
• Leading athletic shoe manufacturers used 3DP models to
communicate and reduce development time.
• Automotive industry utilized 3DP to produce resin-infiltrated
models for function testing.
Voxeljet Systems
• Voxeljet Technology, Germany, is a relatively new company that markets BJ machines
that use polymer and sand powders for concept models, functional models, investment
casting patterns, and sand casting applications.
• Through the powder’s reaction with the binder, the powder immediately hardens in the
machine. The powder supports the part.
• Specifications are shown in Table 8.1.

A part made of
epoxy-infiltrated
PMMA

https://www.youtube.com/watch?v=hjIoGPZPNjU Voxeljet VXC 800 (Source: Voxeljet)

Voxeljet largest machine (VX4000)

▪ Build space: 4 x 2 x 1 m.
▪ Inkjet print head with 26,560 controllable jets;
600dpi in plane (42.3 μm).
▪ Layer height: 150-300 μm.
▪ Vertical print speed: 15.4 mm/h (=123 L/h).
▪ Continuous (24/7) operation with multiple
building platforms.

https://www.youtube.com/watch?v=2Kd7rmPrF_w Voxeljet
Sand Molded Casting

Sand casting, also known as sand molded

casting, is a metal casting process
characterized by using sand as the mold
material. ... The mold cavities and gate
system can be fabricated by compacting
the sand around models called patterns,
or by 3D printing.
Sand form for turbine wheel (Voxeljet)

Voxeljet
ExOne Systems
• The ExOne corporation markets a line of BJ machine that fabricate metal parts from metal powder,
as well as another line of BJ machine for sand casting molds and cores from silica sand.
• Strong polymer binders are required with these heavy powders.
• Applications for the metal material models include prototypes of metal parts and some low-volume
manufacturing, as well as tooling.
• The surface finish of these parts is comparable to PBF parts.
• Finish machining is required for high tolerance and mating surfaces.
• Specifications are shown in Table 8.1.

ExOne, M-Flex
(400× 250× 250 mm)
www.exone.com/Systems
ExOne M-Lab system

Prometal part “engine adapter”;

(Source: IFAM, Bremen)
The ExOne metal and ceramic The component (deviations x, y, z = 170, 65, 90
printer M-Lab. (Source: ExOne) mm3) has a building time of 13 h, a debinding and
sintering time of 11 h, and an infiltration time of 11 h.

• The process itself is cold, but the post-processing include several thermal steps that lead
up to 1230℃ and fundamentally bring distortion with them. But they are good to handle
because they change very slowly and do not produce high local temperature peaks. The
reproducible shrinkage is around 1.5 %. The printing speed is about 1.5 m/s.
• Typical thicknesses of layers for the standard powder are between 100 and 170 μm. The
M-Lab in fine resolution mode builds layers of 50 μm. The single drops can be placed
with an accuracy of 25 μm. Component tolerances up to ± 0.02 % can be reached.
S-Max System
Exercise: Please
share some videos
for the S-Max?

ExOne molding sand printer S-Max ExOne molding sand system for the S-Max:
(Source: ExOne) blender (left), unpacking station (right)
(Source: ExOne)
• The largest machine, the S-Max, is intended for companies with large demands for
castings, such as the automotive, heavy equipment, and oil & gas industries.
• The dimensions of the building spaces of the S-Max are 1800 × 1000 × 700 mm3.
• The building speed is given as 14 to 20 mm/h.
• The thicknesses of the layers are 200 to 250 μm.
• The machines print molds and cores for sand casting. Various metals can be cast into the
printed molds, including aluminum, zinc, and even magnesium.
• The component leaves the machine ready to use. Follow-up processes are not necessary.
Nowadays (ExOne)
Infiltration & Sintering
• After printing is complete, the parts require a secondary process, like
sintering and/or infiltration, to improve the mechanical properties, as
the as-printed parts basically consist of metal particles bound together
with a polymer adhesive.
• The parts are sintered in a furnace, while burning off the binder. It is then
infiltrated with a second molten metal (e.g., copper or bronze) to infiltrate
the voids via capillary action to obtain full density and good strength.
• Post-processing include machining, polishing and coating to enhance
wear and chemical resistance, for example nickel and chrome plating.
➢ Typically, the sintered or infiltrated BJ metal parts may have an internal
porosity. This affects the mechanical properties of metal BJ parts (e.g.,
fatigue, fracture strength, and ductility), as the voids can lead to crack
initiation. Advanced metallurgical processes (e.g., Hot isostatic pressing)
can be applied to produce parts with almost no internal porosity.
Metal Binder Jetting

Adapted from https://www.additively.com/en/learn-about/binder-jetting and Additive Manufacturing Technologies (Gibson, Rosen, Stucker)
Infiltrated vs. Monolithic
Example steps after printing (1/2):
ExOne SS binder jetting with bronze infiltration

1. Curing: build box is placed into an oven for curing of the binder to produce
green strength for handling. Depending on the mass of the component(s), the
curing operation takes 6-12 hours. This can also be performed in situ (i.e.,
scanning heat lamp).

2. Depowdering: after curing, loose metal powder is vacuumed out of the build
box to reveal the part. Air is used to dislodge any loose powder from the part. The
excess metal powder is recycled. The part is fragile, but can be handled.

3. Furnace cycles: the “green” part is removed from the AM machine, then the
part(s) are placed in a graphite crucible, surrounded by support media, and
placed in a vacuum furnace for a total of 24-36 hour cycle of sintering, infiltrating
and annealing. The part are subjected to three furnace cycles: In the first cycle,
low temperature is used for several hours to burn off the polymer binder. In the
second cycle, high temperature is used to lightly sinter (metallurgically bond) the
metal particles together at about 1100℃ so that the part has decent strength. After
sintering the component is ~ 60% dense. At this point, it’s a 3D porous structure.
post-processing
sequence (2/2)

4. Infiltration (optional): in the final cycle, a bronze ingot is placed in the

furnace in contact with the part so that bronze infiltrates into the part’s pores
and fills all remaining voids between the metal particles, resulting in parts
that are 90–95 % dense. Epoxy infiltration is an alternative.

5. Annealing: the final step is to gradually cool the furnace to anneal the
part. Annealing lowers the tensile and yield strength, making the part less
brittle for post machining such as milling, drilling and tapping operations.
The component can also be welded and soldered.

6. Finishing: after processing, the finish of the component is about a 600

μin Ra (15 μmRa) with small printing lines remaining visible. Bead blasting
improves the finish to approximately 300 μin Ra (7.5 μmRa). Barrel finishing
can improve external surfaces to a 50 μin Ra (1.25 μmRa). Hand polishing,
plating, and anticorrosion.
Binding vs. sintering
• Binder application is fast.
• Sintering is slow.
• The “green” parts doesn’t get its
green strength by thermal melting
like in the sintering process, but by
injection the binder in the metal or
ceramic powder.
• The advantage over the sintering
process of multicomponent powders
is that a separation of the building
material and binder segregation in
the powder can be easily performed.
• The process of the machine runs
under environmental conditions and
thus is relatively cold, so there is Sintering model of two uniformly-
minimal thermal distortion. sized, spherical particles
The science of sintering
→ Sintering fuses particles to impart Diffusion and vapor-phase transport
strength to the part.
▪ Controlled atmosphere
▪ Temperature below melting point (70-90%)

Liquid-phase transport

https://www.slideshare.net/spssil/powder-metallurgy-42203766

Sintering Mechanisms
▪ Diffusion (solid-state): Bonding of adjacent particles
▪ Vapor-phase transport: Metal atom
▪ Liquid-phase transport (different materials)

https://www.slideshare.net/aslam1992/u1-p3-powder-metallurgy
The science of sintering
Example: Microstructure and properties of 316L
stainless steel (Single Alloy Metal/Monolithic)

http://www.exone.com
Example: Microstructure and properties of
316 Stainless Steel Infiltrated with Bronze

Bronze = 90% Cu / 10% Sn

http://www.exone.com/Portals/0/ResourceCenter/Materials/X1_MaterialData_316SS_rv4.pdf
Binder jetting bonded sand

ExOne offers a silica sand and two-

part binder, where one part (binder
catalyst) is coated on a layer and
the second part is printed onto the
layer, causing a polymerization
reaction to occur and binding sand
particles together.
https://www.youtube.com/watch?v=LFGnjkoeDng
ExOne Systems
Advantages
• High speed printing: The machine can create multiple parts
simultaneously and not sequentially like laser systems. Build rates can be
up to 85,000 cm3/h.
• Flexible and versatile: Virtually no restriction of design flexibility, for
example, complex internal geometries and undercuts can be created.
• Large parts: Large steel mold parts measuring 1800 × 1000 × 700 mm
can be produced.
• Simple and reliable: There is auto tuning and calibration for maximum
performance and also built-in self-diagnostics and status reporting.
• Quality ceramic and metal parts.

Disadvantages
• Large space required: The machine needs a very large area to house it.
• Limited materials: The system only fabricate parts with its own metal
powder.
• Poor accuracies and surface finishes.
• Extra steps needed to distribute powder.
• Sintering and Infiltration steps are typically needed.
https://www.exone.com/en-US/3d-printing-materials-and-binders
Different parts produced by
BJ from ExOne
Filter Casting
mold block

Heavy
Automobile equipment and
part machinery part
Gibson, Ian, et al. Additive manufacturing technologies. Vol. 17.: Springer, 2021.
HP Multi-Jet Fusion
With depowdering station

Alomarah, et al. "Compressive properties of a novel additively manufactured 3D auxetic structure." Smart Materials and Structures 28.8 (2019): 085019.
HP Multi-Jet Fusion

Alomarah, et al. "Compressive properties of a novel additively manufactured 3D auxetic structure." Smart Materials and Structures 28.8 (2019):
085019.
HP Multi-Jet Fusion

• The HP 3200 series was introduced as the entry model

and it is suitable for RP, while the HP 4200 series
highlights it higher productivity and lower cost per part
as compared to the 3200 series, thus making it ideal for
short-run production as well as RP.
• The carriage that moves in the y-axis is responsible for
coating and fusing of materials in the build area, while
the carriage that moves in the x-axis is responsible for
RAPID 2016
(photos by selective “printing” of multiple agents onto the material
Dave layer within the build area.
Pierson)
HP Systems
Advantages
• High speed printing: HP claims its systems to be 10 times faster than FDM and SLS machine of
similar price range. Instead of selectively depositing materials or energy on one point at a time, HP’s
systems do so by passing its two carriages system through the build area, thereby reducing the part
building time significantly.
• Low cost per part: HP claims to be able to print parts with a cost that is half of those of other FDM
and SLS machines of similar price range. Moreover, the PA12 thermoplastic has high reusability of
80%, thus resulting in lesser powder wastage.
• High-quality functional parts: HP highlights its systems’ closed loop thermal control system, hence
enabling precise thermal control in the build area. The result of this control is high-dimensional
accuracy, good precision and optimal mechanical properties of the printed part.
• High accuracy and fine details: HP’s systems can deposit 30 million extremely fine drops of HP
fusing and detailing agents per second, allowing highly accurate and precise parts to be produced.

Disadvantages
• Limited variation of materials: Only the PA12 multipurpose thermoplastic is available for use.
Nevertheless, HP planned to offer a wider range of thermoplastics as well as fire retardants and
elastomers in the future.
• Needs of post-processing: HP’s printed part has to be cleaned from the part cake as well as cooled
down before any further processes can proceed.
Höganäs “Digital Metal”

< 50 µm resolution
DM Production system (Desktop Metal)

desktopmetal.com https://www.youtube.com/watch?v=W_jcYga95aY
BJ process benefits and drawbacks

Advantages: Drawbacks:
• Faster than MJ. • BJ offers a limited number of
• The capability of printing in color. material selection.
• Bonding occurs at room temperature • Parts tend to have poorer
→ No dimensional distortions. accuracies and surface finishes
• Build volume of BJ machines are than parts made with MJ.
amongst the largest compared to all • Lower mechanical properties than
3D printing technologies (up to 2200 x SLM parts, due to their higher
1200 x 600 mm). porosity; in turn they are not
• BJ requires no support structures. suitable for high-end applications.
• Metal BJ is up to 10x more economical • Only rough details can be printed
than other metal AM processes (SLM). with BJ, as the parts are very brittle
• An advantage of metal BJ compared to in their green state and may
SLM, is the low surface roughness of fracture during post processing.
the produced parts (Ra 6 μm after post-
processing).
Material Jetting vs. Binder Jetting: Which
Jetting Process Should You Choose?

Process? Materials? Main Manufacturers?

Characteristics? Applications? Price?
Material Jetting vs. Binder Jetting: Which
Jetting Process Should You Choose?
Concept Check

1. What is the main difference between MJ and BJ?

2. Is support structures mandatory in the BJ process? Why?
3. List few characteristics of a good binder material.
4. How to achieve a high packing density in the powder bed?
5. Name few post-processing treatments for BJ?
6. What are the three sintering mechanisms in BJ? What are
three major variables that control sintering?
7. Explain all the steps required for binder jetting bonded sand?
8. What is the major weakness of the HP system?
9. What are the main advantages and limitations of the BJ?
10.What is the direct shell production casting?