Metal binder jetting is a 3D printing process that uses powdered metals and a liquid binding agent to produce parts layer by layer. The powder is selectively deposited onto a build platform in the desired shape, and the binder is then applied to join the particles. Unlike high-energy powder bed fusion systems, material consolidation does not happen in the printer—once the build is complete, the entire container is cured, giving the parts enough strength to be gently removed from the powder. The parts are then moved to a vacuum furnace for heat treatment, sintering, and infiltration to remove the binding agent and fuse the particles together, resulting in a fully solid part.
One of binder jetting’s most unique characteristics is its ability to use a very wide variety of materials. Because they are not subjected to high levels of energy, materials that would typically be volatile or prone to degradation can be used. It is also particularly effective for materials that do not typically melt, such as ceramics and composites.
Binder jetting has been around since the early 1990s, originally developed by Ely Sachs and Mike Cima at the Massachusetts Institute of Technology. In 1995, Z Corporation (now owned by 3D Systems) obtained an exclusive license for the process and commercialized it. It has seen an increase in popularity in recent years due to its ability to produce complex geometries and its affordability compared to other metal 3D printing methods. Binder jetting is often used in the production of small metal parts and prototypes, and has a wide range of applications across many industries.
Metal binder jetting 3D printing has a diverse range of applications across many industries.
| Type | Name | Description | MDS |
|---|---|---|---|
Stainless Steel | ExOne 316L Stainless Steel | A 98%+ dense 316L stainless steel metal with superb corrosion resistance, and excellent feature details. | |
Stainless Steel | ExOne X1 Metal 316i™ | 316i is a matrix metal composite material composed of 60% 316L stainless steel and 40% bronze infiltrant. This material offers good mechanical properties and offers excellent wear resistance. 316i is easier to tap and post-machine versus 420i. 316i is 95%+ dense. | |
Stainless Steel | ExOne X1 Metal 420i™ | 420i is a matrix metal composite material composed of 60% 420 stainless steel and 40% bronze infiltrant. This material offers good mechanical properties and offers excellent wear resistance. Its properties behave similarly to 4140 steel. 420i is 95%+ dense. |
Description | Notes |
|---|---|
This table depicts the general tolerances for Metal Binder Jetting. Stresses during the build and other geometry considerations may cause deviation in tolerances and flatness. Part designs with thicker geometries, flat or broad parts, and parts with uneven wall thicknesses may be prone to significant deviations or warp. Improved tolerances may be possible and must be approved on a case-by-case basis. General tolerances apply before secondary finishing or post-processing unless otherwise specified. | |
General tolerance | Parts may shrink 0.8% – 2.5% during cooling depending on their size and geometry. Internal geometries, such as slots and holes, may shrink as much as 5%. |
Build size | Up to 15″ x 10″ x 10″ (381 x 254 x 254 mm) |
Layer height (less than 16″) | 0.004″ (0.1016 mm) |
Surface roughness | 30 to 200 µin Ra depending on build orientation, finish, and material |
Density | 95%+ for infiltrated, 98%+ for single-alloy. Density is homogeneous. |
Feature | Design Guideline |
|---|---|
Unsupported walls | 0.04″ (1.0 mm) |
Supported walls | 0.04″ (1.0 mm) |
Minimum feature size | 0.04″ (1.0 mm) |
Minimum hole diameter | 0.04″ (1.0 mm) |
Minimum escape hole diameter | 0.157″ (4.0 mm) |
Minimum font size | Arial 26 or greater |
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