Binder Jetting Functional Binder Infiltration Porosity Reduction
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Solution Overview
Problem
Traditional binder jetting methods face challenges with porosity, shrinkage, and contamination, leading to compromised mechanical properties in 3D printed products, which limits their functionality and recyclability.
Innovation Solution
A new method of binder jetting using functional binders that infiltrate and fuse powder bed particles in situ, eliminating the need for sacrificial binders and reducing porosity, allowing for the production of functional products with enhanced mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional binder jetting methods are used with sacrificial binders, then the structure can be self-supporting during manufacturing, but the mechanical properties are compromised due to porosity and shrinkage
Solution Approach 1:
The invention changes the fundamental parameter of binder function from sacrificial (temporary support) to permanent (structural component). The binder material composition is modified to become a functional part of the final product, eliminating porosity and shrinkage issues while maintaining self-supporting capability during manufacturing.
Solution Approach 2:
The invention uses composite materials where the binder and build material form an integrated composite structure. The binder is no longer a separate sacrificial component but becomes chemically or physically bonded with the build material to create a unified composite with enhanced mechanical properties.
2Stability of the object's composition
If sacrificial binders are used in binder jetting, then green strength is sufficient for handling, but porosity and contamination occur in the final product
Solution Approach 1:
The invention extracts the sacrificial binder function from the system, eliminating the need for binder removal processes. The binder remains in the final product as a functional component, removing the source of porosity and contamination while maintaining adequate green strength through improved binder-material bonding.
Solution Approach 2:
The invention converts the previously harmful binder (source of porosity and shrinkage) into a beneficial component. The binder's presence is transformed from a defect to be removed into a functional element that contributes to the final product's integrity and performance.
3Loss of substance
If traditional binder jetting with de-binding process is used, then binder removal is achieved, but shrinkage and mechanical property degradation occur
Solution Approach 1:
The invention inverts the traditional approach by not removing the binder at all. Instead of de-binding followed by sintering, the process retains the binder and uses direct sintering or melting, completely reversing the sequence and purpose of the binder removal step.
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
The method achieves significant reduction in porosity and shrinkage, resulting in denser, stronger 3D printed parts suitable for industrial applications, with improved mechanical properties and simplified recycling.
Implementation Method 1
jetting a functional binder onto selected parts of said layer, wherein said functional binder infiltrates into pores in the powder bed
Implementation Method 2
locally fuses particles of the powder bed in situ
Data Source
AI summary
A method of 3D printing comprises: providing a layer of a powder bed; jetting a functional binder onto selected parts of said layer, wherein said binder infiltrates into pores in the powder bed and locally fuses particles of the powder bed in situ; sequentially repeating said steps of applying a layer of powder on top and selectively jetting functional binder, multiple times, to provide a powder bed bonded at selected locations by printed functional binder; and taking the resultant bound 3D structure out of the powder bed.