Inorganic Oxide Powder Composition for Uniform Binder Jetting
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Solution Overview
Problem
Existing binder jetting methods in additive manufacturing face issues with non-uniform distribution of constituent materials, leading to voids and uneven structures, and require powders with high fluidity, uniform layer formation, and low shrinkage during sintering.
Innovation Solution
Inorganic oxide particles with specific particle size distributions and properties, including D50 of 5.5 to 9.0 μm and pressure loss of 1.75 to 2.81 kPa, ensuring appropriate fluidity, shape stability, and bulk density for uniform layer formation and low shrinkage during sintering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the fluidity of powder material is increased to achieve favorable laying property and high density filling, then the uniformity of powder layer improves, but the shape stability during binder application deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling particle size (D50: 5.5-9.0 μm) and surface properties (BET specific surface area: 0.10-10.00 m2/g) of inorganic oxide particles to optimize the balance between fluidity and shape stability, enabling both favorable laying property and shape maintenance during binder application
2Manufacturing precision
If the bulk density of powder material is increased to achieve high density filling, then the uniformity of three-dimensional article improves, but the binder penetration capability deteriorates
Solution Approach 1:
The patent optimizes bulk density to a specific range (2.05-2.65 g/cm3) through controlled particle size distribution and spherical shape (circularity: 0.93-1.00), achieving a balance where the powder is dense enough for uniform filling but still allows adequate binder penetration for proper binding
3Ease of operation
If the particle size of powder material is decreased to improve fluidity, then the laying property improves, but the shrinkage rate during sintering increases
Solution Approach 1:
The patent specifies an optimal particle size range (D50: 5.5-9.0 μm) that provides sufficient fluidity for good laying property while maintaining appropriate particle dimensions to minimize shrinkage rate during sintering, achieving both ease of operation and manufacturing precision
Data Source
AI summary
Inorganic oxide particles having a D50 of 5.5-9.0 μm and a pressure loss of 1.75-2.81 kPa in air permeation at a pressure of 12 kPa.