Setter Assembly Mitigating Thermal Distortion in Binder-Jet Parts
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Solution Overview
Problem
Additive manufacturing techniques, particularly binder jetting, face challenges in maintaining the geometry of complex parts during post-printing thermal processing due to thermally induced distortions such as warping and sagging, which can render consolidated parts unsuitable for use.
Innovation Solution
A setter assembly is used to support binder-jet printed parts during thermal processing, comprising a base, top and bottom setter components, and support pins that allow for dimensional changes, ensuring proper positioning and minimizing distortion by accommodating shrinkage and densification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If binder-jet printed parts are subjected to thermal processing (sintering/debinding), then the parts achieve consolidation and strength, but thermally induced distortions (warping and sagging) occur that compromise geometric integrity
Solution Approach 1:
The support assembly is divided into multiple separable components including a base component, a top component, and intermediate components that can be individually positioned and removed. This segmentation allows the support structure to adapt to different geometric requirements during thermal processing while maintaining part stability.
Solution Approach 2:
The support assembly acts as an intermediary structure between the printed part and the thermal processing environment. It provides mechanical support and constraint to prevent warping and sagging during sintering and debinding, while being removable after processing to reveal the final part.
2Manufacturing precision
If rigid support structures are used to prevent distortion during thermal processing, then geometric integrity is maintained, but the support structures cannot accommodate thermal shrinkage and densification
Solution Approach 1:
The support assembly incorporates dynamic characteristics through its modular design, allowing it to adapt its support geometry during thermal processing. The separable components can be positioned to accommodate shrinkage and densification while maintaining geometric constraint, transitioning from a fixed to an adaptive support system.
Solution Approach 2:
The support assembly uses nested intermediate components that can be positioned within the part cavity or around external features. These nested structures provide support at critical locations while allowing overall dimensional changes during sintering, accommodating both geometric integrity and thermal shrinkage.
3Adaptability or versatility
If complex geometries are printed using binder jetting, then manufacturing flexibility and customization are enhanced, but the parts become more susceptible to thermally induced distortions
Solution Approach 1:
The support assembly provides localized support at critical regions of complex geometries rather than uniform support throughout. Intermediate components can be positioned at specific locations where warping or sagging is most likely to occur, providing targeted geometric stability while maintaining manufacturing flexibility for complex designs.
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 setter assembly effectively mitigates thermally induced distortions, reducing manufacturing costs and improving production yields by maintaining the integrity and geometry of complex parts during sintering and debinding processes.
Implementation Method 1
a length of the support pins decreases in response to thermal processing of the binder-jet printed part
Implementation Method 2
heating the brown body part and the setter assembly above a second temperature to sinter the powder to generate the part
Data Source
AI summary
A method includes assembling a setter assembly onto a binder-jet printed part, wherein the setter assembly includes a base, a top setter, a bottom setter positioned between the base and the top setter, and a support pin extending between the base and the top setter having a terminus that abuts an inward facing surface of the top setter, such that at least portion of the binder-jet printed part is nested between the top setter and the bottom setter. The method includes heating the binder-jet printed part and the setter assembly to debind or sinter the binder-jet printed part, wherein a length of the support pin decreases in response to the heating to move the top setter toward the base.