Design of a Compaction-Assisted Binder Jetting Machine
Abstract
Binder jetting is an additive manufacturing method in which a liquid binder is repeatedly deposited by a printhead onto a thin layer of powder particles to produce components. This technology has gained significant attention due to its potential for low-cost production and its applicability in various industries including electronics, automotive, and energy. However, a major challenge in this process is achieving high-density finished parts. This study aims to enhance the density of parts manufactured using binder jetting by introducing an automated compaction-assisted binder jetting machine (BJ). Compaction is the application of pressure to densify powder particles before the deposition of liquid binder. The objective is to design two configurations of a compaction-assisted BJ machine, Model E and Model P. Model E is designed as a low-budget machine, targeting small labs for concept development, with a compaction pressure of 0.2 MPa. Model P is a heavy-duty machine with a compaction pressure of 1 MPa. The designs encompass a range of aspects including automated functionalities such as powder feeding, powder spreading, powder recycling, powder bed compaction, and binder deposition, as well as mechanical design considerations for the machine structure and linear systems. Additionally, the design process involves careful component selection, covering actuators, print head, servo motors, and stepper motors. The deliverables are a bill of materials (BOM), complete CAD files of the machine, and functional block diagrams. This research contributes to the advancement of BJ technology, offering increased density with efficient solutions.
Collections
Citation
Marzouq, Asem Jamal Ahmad (2023). Design of a Compaction-Assisted Binder Jetting Machine. Master's thesis, Texas A&M University. Available electronically from https : / /hdl .handle .net /1969 .1 /203052.