5 Reasons To Choose Binder Jetting For Metal Parts
In Technical Guides by AZOTH3D
Several Additive Manufacturing/ 3D printing processes can work with metal materials, with each using a different technique to fabricate a final object. Binder jetting introduced a fast way to build parts out of both polymer and metal materials, but here we focus on metal materials.
In brief, binder jetting is a two-step process where the components are printed and densified in separate steps. (see What is Binder Jetting).
While there are a number of reasons to select binder jetting for your project, we’ll look at five: Cost, time to market, design freedom, build quality, and production capability.
Cost
The overall cost of 3D printing a part basically involves the amount of material used, whether there’s a need for support structures, post processing steps, and the overall cost of the machine.
The amount of material used to build a part will depend on the design of a part—it’s size and complexity—and the need for supports for specific features. In this powder bed process, only specific areas of the bed are treated with the jetted binding material. Therefore, some of the metal powder is recoverable and reusable in another build, saving material costs. The powder in the build bed also serves as a support for some features in a design, such as overhangs or certain internal cavities that will be supported by the untreated areas of powder.
Binder jetting also does not require the creation of tooling or fixtures to support a part build, which is both a cost and time savings.
A final binder jetted part requires little to no post processing, saving time and cost at this step. If desired, there are finishing processes mentioned later.
If one is purchasing a 3D printing system, binder jetting systems use less expensive components, such as ink-jet print heads rather than lasers, so these printers tend to be less expensive than other options.
Time To Market
The size and complexity of a part will always be a factor in how quickly it can be brought to market. But binder jetting can speed things up. Binder jetting uses inkjet print heads which can move at high speeds, shortening the overall build time. Shorter build times enable designers to iterate quickly, not only improving the design but getting to the final design within hours or a day or two.
The use of inkjet print heads also means multiple parts can be built simultaneously in the build bed, further speeding up the overall time to market.
And because little to no finishing is needed, the final part is reached more quickly.
Design Freedom and Benefits
One of the key advantages of binder jetting is its ability to print just about anything. For example, additive technologies like binder jetting are known for the ability to build complex geometric shapes, conformal channels, curves, internal voids or entrapped features that don’t require escape holes, and so on. Binder jetting can be used to create designs that reduce weight, combine parts into a complete assembly, and mimic nature.
Binder jetting is especially adept at building machine spare parts, like end of arm grippers for robots, or similar tooling. The advantage here is the ability to build such parts as needed frees up inventory.
With binder jetting, designers can create features of less than 50 mm. Because binder jetted parts undergo a sintering process, larger features may potentially deform in that process.
Protruding features should be designed to avoid possible damage when green parts are handled. But features can be fairly thin if they are well supported within a design; the minimum diameter should not be less than 0.4 mm.
Additive easily handles holes and cavities. The minimum size for these features is mostly limited by the capability to clean out loose powder after printing. Longer or curved channels are harder to clean and will therefor need to be larger.
In the binder jetting process components composed of interlocked or enclosed parts can be manufactured as a single component, eliminating the need for post assembly. A minimum 0.5 mm gap is required between interlocked on enclosed features.
Quality
Feature details, resolutions, surface finish are all features used to evaluate a part’s overall quality.
Binder jetting is capable of printing fine, detailed parts. Surfaces can even contain text, logos and textures. A typical resolution is 35 μm. Minimum feature size as low as 0.1 mm can be printed. Binder jetting typically reaches a dimensional tolerance of ± 0.5% of outer dimension and at best ± 50 μm. Features requiring higher tolerances can be milled after printing.
Binder jetting offers a good surface finish, (3 μm Ra supplied by Azoth). If desired, though, finishing options are available, such as Isotropic Super Finishing (Polishing), that will deliver a final surface finish <1 μm Ra.
While a binder jetting build is supported by unbound powder, intricate geometry parts may require the use of supports in the sintering furnace. The supports, often made of ceramic or separate metal components, are easily removed after sintering.
Quality also involves the mechanical properties of a part. The microstructure of a built part, the size and shape of the final grain, play a role in determining the mechanical property of strength. Binder jetting produces a fine equiaxed grain structure for a more uniform microstructure that delivers an isotropic grain pattern. This pattern means a part is mechanically strong in all directions (X, Y, and Z) and will not fatigue as readily as non-isotropic patterns.
Production
The ability to prototype parts fast is a major application of binder jetting. But this technology is also well suited to the production of parts. It can be used to produce tens of thousands of parts on a production line. Several automotive manufacturers are using binder jetting for various car parts.
As mentioned earlier, binder jetting can produce multiple parts simultaneously as the multiple nozzles of the inkjet system spread the binder material over the whole build bed area. The result is fast production.
Several Additive Manufacturing/ 3D printing processes can work with metal materials, with each using a different technique to fabricate a final object. Binder jetting introduced a fast way to build parts out of both polymer and metal materials, but here we focus on metal materials.
In brief, binder jetting is a two-step process where the components are printed and densified in separate steps. (see What is Binder Jetting).
While there are a number of reasons to select binder jetting for your project, we’ll look at five: Cost, time to market, design freedom, build quality, and production capability.
Cost
The overall cost of 3D printing a part basically involves the amount of material used, whether there’s a need for support structures, post processing steps, and the overall cost of the machine.
The amount of material used to build a part will depend on the design of a part—it’s size and complexity—and the need for supports for specific features. In this powder bed process, only specific areas of the bed are treated with the jetted binding material. Therefore, some of the metal powder is recoverable and reusable in another build, saving material costs. The powder in the build bed also serves as a support for some features in a design, such as overhangs or certain internal cavities that will be supported by the untreated areas of powder.
Binder jetting also does not require the creation of tooling or fixtures to support a part build, which is both a cost and time savings.
A final binder jetted part requires little to no post processing, saving time and cost at this step. If desired, there are finishing processes mentioned later.
If one is purchasing a 3D printing system, binder jetting systems use less expensive components, such as ink-jet print heads rather than lasers, so these printers tend to be less expensive than other options.
Time To Market
The size and complexity of a part will always be a factor in how quickly it can be brought to market. But binder jetting can speed things up. Binder jetting uses inkjet print heads which can move at high speeds, shortening the overall build time. Shorter build times enable designers to iterate quickly, not only improving the design but getting to the final design within hours or a day or two.
The use of inkjet print heads also means multiple parts can be built simultaneously in the build bed, further speeding up the overall time to market.
And because little to no finishing is needed, the final part is reached more quickly.
Design Freedom and Benefits
One of the key advantages of binder jetting is its ability to print just about anything. For example, additive technologies like binder jetting are known for the ability to build complex geometric shapes, conformal channels, curves, internal voids or entrapped features that don’t require escape holes, and so on. Binder jetting can be used to create designs that reduce weight, combine parts into a complete assembly, and mimic nature.
Binder jetting is especially adept at building machine spare parts, like end of arm grippers for robots, or similar tooling. The advantage here is the ability to build such parts as needed frees up inventory.
With binder jetting, designers can create features of less than 50 mm. Because binder jetted parts undergo a sintering process, larger features may potentially deform in that process.
Protruding features should be designed to avoid possible damage when green parts are handled. But features can be fairly thin if they are well supported within a design; the minimum diameter should not be less than 0.4 mm.
Additive easily handles holes and cavities. The minimum size for these features is mostly limited by the capability to clean out loose powder after printing. Longer or curved channels are harder to clean and will therefor need to be larger.
In the binder jetting process components composed of interlocked or enclosed parts can be manufactured as a single component, eliminating the need for post assembly. A minimum 0.5 mm gap is required between interlocked on enclosed features.
Quality
Feature details, resolutions, surface finish are all features used to evaluate a part’s overall quality.
Binder jetting is capable of printing fine, detailed parts. Surfaces can even contain text, logos and textures. A typical resolution is 35 μm. Minimum feature size as low as 0.1 mm can be printed. Binder jetting typically reaches a dimensional tolerance of ± 0.5% of outer dimension and at best ± 50 μm. Features requiring higher tolerances can be milled after printing.
Binder jetting offers a good surface finish, (3 μm Ra supplied by Azoth). If desired, though, finishing options are available, such as Isotropic Super Finishing (Polishing), that will deliver a final surface finish <1 μm Ra.
While a binder jetting build is supported by unbound powder, intricate geometry parts may require the use of supports in the sintering furnace. The supports, often made of ceramic or separate metal components, are easily removed after sintering.
Quality also involves the mechanical properties of a part. The microstructure of a built part, the size and shape of the final grain, play a role in determining the mechanical property of strength. Binder jetting produces a fine equiaxed grain structure for a more uniform microstructure that delivers an isotropic grain pattern. This pattern means a part is mechanically strong in all directions (X, Y, and Z) and will not fatigue as readily as non-isotropic patterns.
Production
The ability to prototype parts fast is a major application of binder jetting. But this technology is also well suited to the production of parts. It can be used to produce tens of thousands of parts on a production line. Several automotive manufacturers are using binder jetting for various car parts.
As mentioned earlier, binder jetting can produce multiple parts simultaneously as the multiple nozzles of the inkjet system spread the binder material over the whole build bed area. The result is fast production.
Several Additive Manufacturing/ 3D printing processes can work with metal materials, with each using a different technique to fabricate a final object. Binder jetting introduced a fast way to build parts out of both polymer and metal materials, but here we focus on metal materials.
In brief, binder jetting is a two-step process where the components are printed and densified in separate steps. (see What is Binder Jetting).
While there are a number of reasons to select binder jetting for your project, we’ll look at five: Cost, time to market, design freedom, build quality, and production capability.
Cost
The overall cost of 3D printing a part basically involves the amount of material used, whether there’s a need for support structures, post processing steps, and the overall cost of the machine.
The amount of material used to build a part will depend on the design of a part—it’s size and complexity—and the need for supports for specific features. In this powder bed process, only specific areas of the bed are treated with the jetted binding material. Therefore, some of the metal powder is recoverable and reusable in another build, saving material costs. The powder in the build bed also serves as a support for some features in a design, such as overhangs or certain internal cavities that will be supported by the untreated areas of powder.
Binder jetting also does not require the creation of tooling or fixtures to support a part build, which is both a cost and time savings.
A final binder jetted part requires little to no post processing, saving time and cost at this step. If desired, there are finishing processes mentioned later.
If one is purchasing a 3D printing system, binder jetting systems use less expensive components, such as ink-jet print heads rather than lasers, so these printers tend to be less expensive than other options.
Time To Market
The size and complexity of a part will always be a factor in how quickly it can be brought to market. But binder jetting can speed things up. Binder jetting uses inkjet print heads which can move at high speeds, shortening the overall build time. Shorter build times enable designers to iterate quickly, not only improving the design but getting to the final design within hours or a day or two.
The use of inkjet print heads also means multiple parts can be built simultaneously in the build bed, further speeding up the overall time to market.
And because little to no finishing is needed, the final part is reached more quickly.
Design Freedom and Benefits
One of the key advantages of binder jetting is its ability to print just about anything. For example, additive technologies like binder jetting are known for the ability to build complex geometric shapes, conformal channels, curves, internal voids or entrapped features that don’t require escape holes, and so on. Binder jetting can be used to create designs that reduce weight, combine parts into a complete assembly, and mimic nature.
Binder jetting is especially adept at building machine spare parts, like end of arm grippers for robots, or similar tooling. The advantage here is the ability to build such parts as needed frees up inventory.
With binder jetting, designers can create features of less than 50 mm. Because binder jetted parts undergo a sintering process, larger features may potentially deform in that process.
Protruding features should be designed to avoid possible damage when green parts are handled. But features can be fairly thin if they are well supported within a design; the minimum diameter should not be less than 0.4 mm.
Additive easily handles holes and cavities. The minimum size for these features is mostly limited by the capability to clean out loose powder after printing. Longer or curved channels are harder to clean and will therefor need to be larger.
In the binder jetting process components composed of interlocked or enclosed parts can be manufactured as a single component, eliminating the need for post assembly. A minimum 0.5 mm gap is required between interlocked on enclosed features.
Quality
Feature details, resolutions, surface finish are all features used to evaluate a part’s overall quality.
Binder jetting is capable of printing fine, detailed parts. Surfaces can even contain text, logos and textures. A typical resolution is 35 μm. Minimum feature size as low as 0.1 mm can be printed. Binder jetting typically reaches a dimensional tolerance of ± 0.5% of outer dimension and at best ± 50 μm. Features requiring higher tolerances can be milled after printing.
Binder jetting offers a good surface finish, (3 μm Ra supplied by Azoth). If desired, though, finishing options are available, such as Isotropic Super Finishing (Polishing), that will deliver a final surface finish <1 μm Ra.
While a binder jetting build is supported by unbound powder, intricate geometry parts may require the use of supports in the sintering furnace. The supports, often made of ceramic or separate metal components, are easily removed after sintering.
Quality also involves the mechanical properties of a part. The microstructure of a built part, the size and shape of the final grain, play a role in determining the mechanical property of strength. Binder jetting produces a fine equiaxed grain structure for a more uniform microstructure that delivers an isotropic grain pattern. This pattern means a part is mechanically strong in all directions (X, Y, and Z) and will not fatigue as readily as non-isotropic patterns.
Production
The ability to prototype parts fast is a major application of binder jetting. But this technology is also well suited to the production of parts. It can be used to produce tens of thousands of parts on a production line. Several automotive manufacturers are using binder jetting for various car parts.
As mentioned earlier, binder jetting can produce multiple parts simultaneously as the multiple nozzles of the inkjet system spread the binder material over the whole build bed area. The result is fast production.
Several Additive Manufacturing/ 3D printing processes can work with metal materials, with each using a different technique to fabricate a final object. Binder jetting introduced a fast way to build parts out of both polymer and metal materials, but here we focus on metal materials.
In brief, binder jetting is a two-step process where the components are printed and densified in separate steps. (see What is Binder Jetting).
While there are a number of reasons to select binder jetting for your project, we’ll look at five: Cost, time to market, design freedom, build quality, and production capability.
Cost
The overall cost of 3D printing a part basically involves the amount of material used, whether there’s a need for support structures, post processing steps, and the overall cost of the machine.
The amount of material used to build a part will depend on the design of a part—it’s size and complexity—and the need for supports for specific features. In this powder bed process, only specific areas of the bed are treated with the jetted binding material. Therefore, some of the metal powder is recoverable and reusable in another build, saving material costs. The powder in the build bed also serves as a support for some features in a design, such as overhangs or certain internal cavities that will be supported by the untreated areas of powder.
Binder jetting also does not require the creation of tooling or fixtures to support a part build, which is both a cost and time savings.
A final binder jetted part requires little to no post processing, saving time and cost at this step. If desired, there are finishing processes mentioned later.
If one is purchasing a 3D printing system, binder jetting systems use less expensive components, such as ink-jet print heads rather than lasers, so these printers tend to be less expensive than other options.
Time To Market
The size and complexity of a part will always be a factor in how quickly it can be brought to market. But binder jetting can speed things up. Binder jetting uses inkjet print heads which can move at high speeds, shortening the overall build time. Shorter build times enable designers to iterate quickly, not only improving the design but getting to the final design within hours or a day or two.
The use of inkjet print heads also means multiple parts can be built simultaneously in the build bed, further speeding up the overall time to market.
And because little to no finishing is needed, the final part is reached more quickly.
Design Freedom and Benefits
One of the key advantages of binder jetting is its ability to print just about anything. For example, additive technologies like binder jetting are known for the ability to build complex geometric shapes, conformal channels, curves, internal voids or entrapped features that don’t require escape holes, and so on. Binder jetting can be used to create designs that reduce weight, combine parts into a complete assembly, and mimic nature.
Binder jetting is especially adept at building machine spare parts, like end of arm grippers for robots, or similar tooling. The advantage here is the ability to build such parts as needed frees up inventory.
With binder jetting, designers can create features of less than 50 mm. Because binder jetted parts undergo a sintering process, larger features may potentially deform in that process.
Protruding features should be designed to avoid possible damage when green parts are handled. But features can be fairly thin if they are well supported within a design; the minimum diameter should not be less than 0.4 mm.
Additive easily handles holes and cavities. The minimum size for these features is mostly limited by the capability to clean out loose powder after printing. Longer or curved channels are harder to clean and will therefor need to be larger.
In the binder jetting process components composed of interlocked or enclosed parts can be manufactured as a single component, eliminating the need for post assembly. A minimum 0.5 mm gap is required between interlocked on enclosed features.
Quality
Feature details, resolutions, surface finish are all features used to evaluate a part’s overall quality.
Binder jetting is capable of printing fine, detailed parts. Surfaces can even contain text, logos and textures. A typical resolution is 35 μm. Minimum feature size as low as 0.1 mm can be printed. Binder jetting typically reaches a dimensional tolerance of ± 0.5% of outer dimension and at best ± 50 μm. Features requiring higher tolerances can be milled after printing.
Binder jetting offers a good surface finish, (3 μm Ra supplied by Azoth). If desired, though, finishing options are available, such as Isotropic Super Finishing (Polishing), that will deliver a final surface finish <1 μm Ra.
While a binder jetting build is supported by unbound powder, intricate geometry parts may require the use of supports in the sintering furnace. The supports, often made of ceramic or separate metal components, are easily removed after sintering.
Quality also involves the mechanical properties of a part. The microstructure of a built part, the size and shape of the final grain, play a role in determining the mechanical property of strength. Binder jetting produces a fine equiaxed grain structure for a more uniform microstructure that delivers an isotropic grain pattern. This pattern means a part is mechanically strong in all directions (X, Y, and Z) and will not fatigue as readily as non-isotropic patterns.
Production
The ability to prototype parts fast is a major application of binder jetting. But this technology is also well suited to the production of parts. It can be used to produce tens of thousands of parts on a production line. Several automotive manufacturers are using binder jetting for various car parts.
As mentioned earlier, binder jetting can produce multiple parts simultaneously as the multiple nozzles of the inkjet system spread the binder material over the whole build bed area. The result is fast production.