Binder Jet Printing Internal Channels Using Sacrificial Support Agent
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Solution Overview
Problem
Current binder jetting additive manufacturing techniques face challenges in forming internal channels within printed parts, as depowdering and machining can lead to part damage, increased costs, and reduced yields due to insufficient handling strength and complexity in creating microstructures.
Innovation Solution
The method involves using a channel support agent that is selectively printed and later removed during heat treatment to create internal channels in situ, eliminating the need for depowdering and machining, and utilizing an anti-sintering agent to prevent particle consolidation, allowing for the formation of channels with precise geometry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If depowdering and machining are used to form internal channels, then channels can be created, but part damage occurs and handling strength is insufficient
Solution Approach 1:
The patent applies preliminary action by depositing the channel support agent solution into the green body part before final sintering. This creates a sacrificial framework that defines the channel geometry in advance, allowing channels to form automatically during binder removal without subsequent machining or depowdering operations that would compromise part integrity.
Solution Approach 2:
The channel support agent acts as an intermediary material that temporarily occupies the space where channels will eventually form. This intermediary substance enables precise channel definition during printing while being removable without damaging the final part structure, resolving the contradiction between precise channel formation and part integrity.
2Manufacturing precision
If complex machining processes are used to create microstructures, then internal channels can be formed, but manufacturing costs increase and production yields decrease
Solution Approach 1:
The patent replaces mechanical machining processes with a chemical/deposition-based approach. The channel support agent solution is selectively deposited into the green body using binder jetting technology, eliminating the need for complex mechanical machining or depowdering operations. This substitution maintains microstructure precision while dramatically improving production yield by avoiding part damage during post-processing.
3Ease of manufacture
If traditional binder jetting is used without channel support agent, then printing process is simple, but internal channels cannot be formed in situ
Solution Approach 1:
The patent applies universality by using the binder jetting system to perform multiple functions: depositing both the binder solution for green body formation and the channel support agent solution for channel definition. This multi-functionality allows internal channels to be formed in situ during the printing process itself, maintaining process simplicity while achieving precise channel geometry without requiring additional specialized equipment or post-processing steps.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces manufacturing costs and complexity, enhances production yields, and minimizes defects by creating internal channels during the printing process, improving the integrity and flexibility of the final product.
Implementation Method 1
selectively printing a binder solution comprising a binder into the layer of powder in a first pattern to generate a printed layer
Implementation Method 2
heating the green body part above a first temperature to remove the binder and generate a brown body part
Implementation Method 3
heating the brown body part above a second temperature to sinter the powder to generate the part
Implementation Method 4
heating the green body part above a first temperature to remove the binder and generate a brown body part having the internal channel generated from removal of the channel support agent
Data Source
AI summary
A method of binder jet printing a part includes depositing a layer of a powder on a working surface and selectively printing a binder solution comprising a binder into the layer of powder in a first pattern to generate a printed layer. The pattern is representative of a structure of a layer of the part. The method also includes selectively printing a channel support agent solution comprising a channel support agent into the layer of powder to generate a green body. The channel support agent is selectively printed in a second pattern representative of an internal channel of the part. The method further includes heating the green body part above a first temperature to remove the binder and generate a brown body part and heating the brown body part above a second temperature to sinter the powder to generate the part having the internal channel generated from removal of the channel support agent.