What Is Metal Binder Jetting?

It is an advanced additive manufacturing technique that revolutionises the production of metal components.

This innovative process uses a combination of metal powders and a binding agent to synthesise the components layer by layer, offering unique advantages over traditional manufacturing methods.

In this detailed blog, we’ll delve into what it is, how it works, its benefits, and its applications.

What’s in this blog – Key Takeaways:

1. What Is It?
2. How It Works
3. Why It’s Useful
4. Its Applications

Exploring the Fundamentals

How & When Did This Originate?

This technology has its roots in 1993 in which the Massachusetts Institute of Technology (MIT) came up with an ink jet-based process for creating three-dimensional objects from metal powders.

Interestingly, MIT coined the term “3D Printing” to describe this innovative approach.

In 1996, the manufacturing company Extrude Hone Corporation acquired an exclusive license for MIT’s technology and went on to develop and commercialise systems. Their first 3D printer, the ProMetal RTS‐300, was delivered to Motorola in 1999.

For several years, ExOne, which emerged as a spin-off from Extrude Hone Corporation in 2005, was the sole provider of these services and systems. It wasn’t until the early 2010s, when the original MIT patents began to expire, that new companies entered the market.

Since then, it has seen a resurgence, with a renewed focus on making the technology suitable for widespread production across various industries.

What Is The Process Behind It?

1. The working involves selectively applying a liquid binder to metal powder particles, layer by layer, to build up a part.
2. It starts with depositing a thin layer of metal powder across the build platform.
3. Printheads then deposit droplets of binder onto the powder in specific patterns to bond the particles together.
4. After each layer of binder is applied, the printing plate lowers, and another layer of powder is spread on top. This layering continues until the part is fully formed.
5. Once printed, the part remains in a fragile “green” state and requires additional post-processing, such as sintering and infiltration, to strengthen it.
6. It can be used with various materials beyond metals, including sand and ceramics. The unused powder—about 95%—is typically recycled for future use.

Why Opt for It?

Here are some advantages:

1. Speedy Production

This technique stands out for its impressive speed, capable of producing parts up to 100 times faster than traditional laser-based printing methods. This efficiency is thanks to advanced printheads that speed up the manufacturing process.

2. Cost-Effective for Large Runs

When manufacturing parts in high volumes, it can provide a cost per part that rivals or even surpasses traditional methods like casting and forging. This makes it a great choice for large-scale production.

3. Impressive Detail Resolution

With the ability to deposit up to 670 million drops of binder per second, it delivers exceptional detail and precision, allowing for the creation of intricate parts with high resolution.

4. Versatile Material Options

This method utilises a broad range of materials from the established metal injection moulding (MIM) supply chain. This versatility ensures compatibility with various metal alloys, broadening its application possibilities.

5. Uniform Material Strength

Parts produced through this process feature consistent material properties and strength comparable to those made by traditional casting methods, ensuring reliability and durability.

6. High Production Capacity

Thanks to its speed and ability to process large build areas, it is renowned for its high production throughput, making it ideal for extensive manufacturing needs.

Applications

It is a versatile technology that can be utilised for a wide-ranging application across various industries. Its ability to produce complex, high-resolution parts makes it an excellent choice for different fields. Here are some of the notable applications:

1. Prototyping
2. Aerospace Parts
3. Cores and Moulds
4. Tool Manufacturing
5. Casting Patterns
6. Jewellery Design
7. Colourful Decorative Items

The Bottom Line

Metal binder jetting is a major step forward in this technology, known for its speed, cost-effectiveness, and versatility. Layering metal powders and a binding agent creates detailed and complex metal parts. As this technology develops, it will continue to grow in various industries, leading to more innovations in manufacturing.

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