Binder Jetting Plug Sintering for Additive Manufacturing
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Solution Overview
Problem
The existing method for manufacturing additively manufactured objects requires welding a plug to the fabricated object after sintering, increasing manufacturing costs and process complexity.
Innovation Solution
A method that forms a precursor with an opening portion, removes unsolidified powder, applies a liquid binder to the plug and opening portion, assembles the plug, and sintering to close the opening without welding, using binder jetting technology.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding is used to close the opening portion after sintering, then the opening can be sealed, but manufacturing costs increase and process complexity increases
Solution Approach 1:
The plug is prepared with a binder coating in advance before assembly. The liquid binder is applied to the outer peripheral wall of the plug and inner peripheral wall of the opening portion beforehand, so that when the plug is inserted and sintering occurs, the binding action is already prepared to ensure proper sealing without requiring post-sintering welding operations.
Solution Approach 2:
The method changes the physical and chemical state of the binding material from solid weld filler to liquid binder coating. By applying the liquid binder to the plug and opening portion surfaces before assembly and then sintering, the material transitions to a bonded state that seals the opening without requiring welding processes, thereby reducing process complexity while maintaining sealing reliability.
2Reliability
If welding is used to close the opening portion after sintering, then the opening can be sealed, but manufacturing costs increase
Solution Approach 1:
The patent replaces the mechanical welding process with a binder jetting-based chemical bonding process. Instead of using welding heat and filler material to seal the opening, the liquid binder is applied to the plug and opening portion, and sintering creates a bonded seal through the binder's binding action, eliminating the need for welding equipment and processes, thereby reducing manufacturing costs while achieving reliable sealing.
3Ease of manufacture
If plug is assembled before sintering, then closure can be achieved, but binding strength may be insufficient without welding
Solution Approach 1:
The liquid binder is applied to the outer peripheral wall of the plug and inner peripheral wall of the opening portion before assembly. This preliminary coating ensures that when the plug is inserted into the opening portion during sintering, the binder is already in position to create strong bonds between the plug and precursor, eliminating the need for post-sintering welding while achieving sufficient bond strength.
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
Enables easy closure of the opening portion by sintering, reducing manufacturing costs and process complexity by eliminating the need for welding.
Implementation Method 1
jetting a liquid binder onto a powder layer to form solidified layers
Implementation Method 2
sintering the precursor having the plug assembled with the opening portion
Data Source
AI summary
The method for manufacturing an additively manufactured object includes: forming a precursor having an opening portion that communicates with an internal space, by jetting a liquid binder onto a powder layer to form solidified layers and stacking the formed solidified layers; forming a plug configured to be assembled with the opening portion; removing unsolidified powder remaining in the internal space from the opening portion; applying the liquid binder to an outer peripheral wall of the plug after removing the unsolidified powder; assembling the plug with the opening portion such that the outer peripheral wall of the plug comes into contact with an inner peripheral wall of the opening portion; and sintering the precursor having the plug assembled with the opening portion.