Binder jetting is the ideal metal 3D printing process for manufacturing very detailed, small, complex metal components.
Use these guidelines to size walls, holes, channels, text and exit holes so your part prints, depowders and sinters reliably.
Learn more about Binder Jetting at Azoth
Binder Jetting Specs at a Glance
| Optimal part size | 5mm to 75mm |
|---|---|
| Recommended maximum | 150mm in the longest dimension, larger parts considered case by case |
| Minimum wall thickness | 0.30mm |
| Minimum hole diameter | 0.20mm |
| Minimum inaccessible internal channel | 3mm diameter |
| Materials | 17-4PH, 316L, pure copper, Mar M247, D2 tool steel |
Binder Jetting Part Size
Small and complex parts are Azoth's specialty. As a rule of thumb, 5mm to 75mm is optimal (about the size of your fist or smaller). We recommend not exceeding 150mm in the longest dimension, though larger components are considered case by case.
Binder Jetting Materials
- 17-4PH Stainless Steel
- 316L Stainless Steel
- Pure Copper
- Mar M247
- D2 Tool Steel
Data sheets are available on the Materials page.
What to Send Us for Binder Jetting
Send your CAD file and a blueprint if one is available. An engineer with binder jetting expertise will evaluate your part, and Azoth will provide DFAM when needed. See File Preparation for accepted file types.
Binder Jetting Design Rules
Binder Jetting Wall Thickness
Minimum wall thickness should be no less than 0.30mm on any cross-section of any part feature. This also applies to minimum distances between walls. Requirements may vary depending on size and feature shape.
Hole Size & Internal Channels
The minimum hole size achievable is 0.20mm in diameter. Inaccessible internal channels should be no less than 3mm in diameter. These values depend on depth, surrounding geometry, and accessibility of the feature.
Edges & Corners
Sharp edges are prone to chipping prior to sintering and likely to propagate cracks. Adding fillets and chamfers to all sharp edges and corners minimizes risk without adding any additional cost or lead time.
Aspect Ratio
An aspect ratio is the proportion of a feature's dimensions, the larger one dimension is versus another, the larger the aspect ratio. The maximum recommended ratio depends on the feature type:
| Feature | Maximum Recommended Ratio |
|---|---|
| Height-to-Wall Thickness | ≤ 8:1 |
| Slot Depth-to-Width (< 2mm width) | ≤ 4:1 |
| Slot Depth-to-Width (> 2mm width) | ≤ 8:1 |
| Hole Depth-to-Diameter (< 2mm dia.) | 4:1 |
| Hole Depth-to-Diameter (> 2mm dia.) | 8:1 |
Features exceeding the recommended ratio are likely to fail, more prone to fracture, hard to depowder, and susceptible to warping during sintering. Enclosed walls, supports, gussets, and ribs can minimize risk.
Text & Surface Texture
Part numbers, logos, and patterns can be easily implemented at no additional cost. Surface textures can also be added for a unique look or improved functionality.
Debossed text: spacing at least 0.3mm apart at all cross-sections, embedded a minimum of 0.4mm for legibility. Letters with free-standing posts (e.g. “A”) must follow the 8:1 aspect-ratio criterion.
Embossed text: spacing at least 0.3mm apart at all cross-sections, following the 8:1 design ratio for lettering height.
Best fonts: Arial Rounded MT Bold, Arial Black, Calibri.
Exit Holes
Exit holes provide an opening for excess powder to escape during depowdering. Without them, interior channels can only reach so deep before powder removal becomes challenging, risking craters on walls, eroded threads, and rounded corners.
What to Expect from Binder Jetted Parts
- Sintering creates a fully dense metal component, ready for its end-use application or further post-processing.
- Every additive part is measured, and every part ships with a certificate of inspection.
- Azoth operates to industry material standards like MPIF 35 and ASTM B883.
Binder Jetting Pre-Flight Checklist
Review this list before you send your part.
- The part is within 150mm in its longest dimension (5mm to 75mm is optimal)
- Walls, and the gaps between walls, are at least 0.30mm
- Holes are at least 0.20mm in diameter, and inaccessible internal channels are at least 3mm
- Sharp edges and corners have fillets or chamfers
- Walls, slots and holes stay within the recommended aspect ratios
- Text is spaced at least 0.3mm apart, and debossed text is at least 0.4mm deep
- Internal channels and cavities have exit holes for powder removal
- The CAD file is an accepted type (see File Preparation)
Next Steps in the Azoth Workflow
The steps that can follow Binder Jetting in Azoth's vertically integrated workflow.
Still Have Questions?
Contact us today and our Applications Engineering team will get back to you as soon as possible.