Abstract
Binder jetting (BJ) has demonstrated high competitiveness among additive manufacturing processes on account of its high production rate at a low material cost. However, both the design procedure and the process for BJ have to be further developed, aiming towards the proper control of the geometrical and dimensional precision and accuracy of the final product. This paper aims to study the factors that affect the flatness form error. Five geometries were designed to obtain planes that were inclined with respect to the fabrication direction. These planes were measured by a coordinate measuring machine in both the green and sintered state, deriving the best-fitting plane and the flatness form error. The analysis of the green samples demonstrates the prevailing influence of saturation level and layer shifting on flatness form error. In the sintered parts, a dimensional change in sintering can determine shape distortion, or an increment in the surface irregularity observed in the green state. The experimental results clearly evidence the effect of both printing and sintering on the quality of the final product, which should be considered when designing parts to be produced using BJ technology.
Highlights
The new potential and opportunities of Additive Manufacturing (AM) technologies are currently under investigation in different production fields [1,2]
binder jetting (BJ) can theoretically process any type of metal and ceramic powder feedstock, guarantee a high production rate, and the printing operation does not require a high-energy source or controlled atmosphere [4]
Gas-atomized stainless steel AISI316L was used to fabricate five different geometries using the binder jetting process. These samples were designed to show a plane with the same nominal size, inclined at five different angles with respect to the fabrication direction
Summary
The new potential and opportunities of Additive Manufacturing (AM) technologies are currently under investigation in different production fields [1,2]. According to these studies, one fundamental challenge concerns the identification of the most suitable AM technique on the basis of the product’s requirements and characteristics [3], as different. The as-built product encounters high dimensional changes on sintering, which can detrimentally affect the product’s quality [4,5]. For these reasons, the success of BJ technology depends on the future development of design methods accounting for dimensional changes and on the related process set-up
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