Metal Binder Jetting: A realistic method for 3D printing in volume production
How it works:
An industrial printhead selectively deposits a liquid binding agent onto a thin layer of metal powder particles to build high-value and one-of-a-kind parts and tooling. The process is repeated layer by layer, using a map from a digital design file, until the object is complete. Metal materials are cured and sintered after printing to achieve densities greater than 97%, in line with metal injection molding (MIM) and better than investment castings.
Why Metal Binder Jetting?
ADVANTAGES OF THE TECHNOLOGY:
- Quick print speeds for volume production output
- Parts with internal geometries
- Design freedom for complex designs
- Greater complexity and better surface finish and feature details compared to investment casing designs
- Wide range of material possibilities
- Geometries that are difficult to produce in hard tooling
- Larger sized components for production
- No required initial tooling or retooling
Our Technology Portfolio
Industrialized 3D Printing Systems
Unlocking complex part designs for volume production in metal binder jetting.
- Build area of 800 x 500 x 400 mm (31.5 x 19.7 x 15.8 in)
- Serial production through our fully automated cell with continuous sintering
- Suitable for medium-sized production, R&D and prototyping
- Build area of 400 x 250 x 250 mm (15.75 x 9.84 x 9.84 in)
In-House Metallurgy Processes
Enabling high volume Binder Jetting with 250,000 sq ft of metallurgical operations.
DSB Technologies holds the world's largest installed capacity of high temperature sintering furnaces - a core process step needed for most metal Binder Jetting alloys.
With over 40 years of metallurgy experience, we bring an extensive infrastructure of processes and equipment to support volume production of metal additive manufacturing every step of the process, from designing for AM to post-printing sintering and secondary machining.
The largest capacity of high temperature sintering in North America coupled with over 40 years of metallurgical expertise
Broad range of material availability, new material and alloy development, and strong interest in lightweighting applications
In-house printing, sintering, secondary machining, and automation to lead volume production in Metal Binder Jetting
Metal Binder Jetting: Design Features
Because of the process's capabilities to support parts through sintering and control distortion, Binder Jetting allows for design freedom to create undercuts, complex internal channels, lattices, sharp edges and corners, surface textures, and fine features.
Reduced Support Structures
Binder Jetting minimizes the support structures needed by using the powder bed itself to support the part while printing. Sinter support structures can also be printed at the same time - separate from the part - to reduce the need for support structure removal after printing and sintering.
To ensure part accuracy, we have the ability to manage shrinkage during sintering. Also, post-sintering secondary operations can support qualifying key dimensions and addressing surface finish requirements.
Thinner Wall Thickness
Thinner wall thicknesses aid in the removal of the binder prior to sintering, and more uniform wall thicknesses minimize the potential for distortion and cracking during sintering.
Binder Jetting print speeds are much faster than competing additive processes, opening the door for the possibility of higher volumes and more cost-competitive finished parts.
With the ability for iterative design changes in a single build, Binder Jetting eliminates the need for expensive upfront tooling costs and retooling - significantly reducing lead times.
Binder Jetting excels at producing parts with internal geometries as the powder acts as the support structure to the internal cavities and is easy to remove as long as there is some open passageway to the surface.
Binder Jetting supports light-weighting not only by controlling the fill ratio through lattice structures, but also by providing a porous initial structure that can be sintered to maintain the porous structure, infiltrated to create a composite structure, or sintered to high density.