Abstract
Binder jetting is ideally suited to produce individual components, as it offers the possibility to directly achieve highly complex geometries. To assure the direct production of net-shape components with optimized process parameters, numerical models across scales were developed in this study to model and simulate each manufacturing step on the entire process chain. Using discrete element and finite element methods, the powder spreading process and the subsequent sintering process were simulated. By considering the influences of the density distribution on green bodies, the gravity, and the friction between the sintering substrate and the sintering parts, the sintering shrinkage and the final geometry could be precisely predicted. The results from simulation were validated with experimental data from both manufacturing steps. With the help of the inverse optimisation, the geometry of the green parts was optimised iteratively, which allows the net-shape components with the desired geometries being manufactured despite sintering distortion.
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