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.
Highlights
Binder Jet Additive Manufacturing (BJAM) is a versatile Additive manufacturing (AM) technique that can form parts from a variety of powdered materials including metals, ceramics, and polymers
Silica sand is an attractive powdered material that can be readily processed using BJAM, and it is especially suited for creating tools and dies due to its low coefficient of thermal expansion (CTE) coupled with its low cost[10,11,12]
15 wt% PEI in 75:25 of water:1-propanol was identified as the optimal binder formulation (Supplementary Fig. 2)
Summary
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. The functionality enables the PEI binder to form strong green parts with silica sand, allows for reactive secondary infiltration, and exhibits washout functionality. 15 wt% PEI in 75:25 of water:1-propanol was identified as the optimal binder formulation (Supplementary Fig. 2).
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