On-Demand: The Metal Binder Jetting Process Explained
Video Transcript with Timestamps
Metal Binder Jetting: From Design to Finished Part
0:05
With advancements in technology, the industrialization of metal binder jetting is now feasible. In order to leverage these processes for metal binder jetting, the part must be designed to take advantage of the technology.
In this video, we will demonstrate the entire metal binder jetting process, from design to finished product.
0:25
As you will see in this video, DSB is uniquely equipped to facilitate every step of this process in our manufacturing facility in Janesville, Wisconsin, providing our customers with a one-stop manufacturing solution.
DSB Technology Center
0:47
Our approach to one-stop manufacturing encompasses the process from concept to final production. Because of this, we’ve established our new Technology Center.
This center has four primary purposes.
1:01
The first is to test and develop new materials, as well as create sintering profiles.
1:08
The second is to collaborate with customers in product development. We have a standing invitation to all of our customers and industry partners to come on-site and work with our team in our new Technology Center to develop and improve product concepts.
1:24
The third purpose is small-scale production. Whether our customers are looking to test a new product in the market or test the robustness of a new design, we are able to support their efforts.
1:37
The final purpose of our center is serial production. Once an application has been optimized, we are able to support our customers with volume production.
Metal Binder Jetting Equipment
1:56
Let’s take a look at the equipment we have in our new Technology Center.
2:01
Our Innovent+ printer, with a small build box, is ideal for R&D, part samples, and prototyping.
2:12
Our 25 Pro printer, which will be featured in this video, is suitable for small-scale production as well as R&D. It has a build space of 400 millimeters by 250 millimeters by 250 millimeters tall.
2:30
Coming soon to our new Technology Center is our 160 Pro printer. This printer is intended for serial production with a build box of 800 millimeters by 500 millimeters by 400 millimeters tall. It has approximately two-and-a-half times the build volume of competing systems.
2:51
Our Elnik vacuum furnace is programmable, which allows us to optimize the sinter cycle for alloy development. This furnace allows DSB to develop furnace profiles as well as run small-batch production.
3:07
The last piece of equipment in our new Technology Center is our fully automated molding cell, which is used to develop metal injection molding and other specialized processes.
3:21
DSB is committed to investing in new technology and expanding our capabilities. As these capabilities grow, so will the equipment in our Technology Center.
Designing a Part for Metal Binder Jetting
3:34
Now that we’ve introduced our Technology Center, we will explore a potential metal binder jetting part.
This urea flange was selected because of its potential for lightweighting and net-shape production, which can be leveraged through the metal binder jetting process.
3:51
This is an example of a urea flange designed by a customer. We can note the symmetrical outside features.
4:04
On the top of the part, we can see a counterbore and three flanges. On the bottom of the part, we have a cone.
4:21
On the left, we can see the part DSB designed for metal binder jetting. The outside of the part contains the same symmetrical features, but with considerable lightweighting.
4:34
The top of the part has the same counterbore and three flanges, but with lightweighted features. The bottom of the part contains the same cone feature.
4:49
Let’s take a deeper look at the 3D models of both parts.
4:54
As mentioned before, both parts contain the same key features: three mounting flanges, a counterbore on the top of the part, and a cone on the bottom.
5:08
With the design freedom of metal binder jetting, the part was lightweighted. As a result, the part has a constant wall thickness throughout, and all unnecessary material was removed from the center of the three flanges.
5:22
In addition, the key features can be printed in their net shape. The metal binder jet design could not be produced using conventional manufacturing methods due to the undercuts in the part and hard-to-reach machining areas.
Preparing the Metal Binder Jet Build
5:42
Once the design is complete, the CAD format is converted to an STL file. This allows us to transfer the data to our printer via USB.
5:54
The flexibility of metal binder jetting allows us to tailor the print for specific purposes.
One example is printing different types of parts or different versions of the same part within a single build box. This unique advantage of metal binder jetting provides development and production flexibility.
6:17
A second example is a tightly packed layer of a single design. By closely nesting the parts, printer throughput can be optimized.
6:33
A third example is a full build box containing the same part. This allows us to maximize printer throughput while also reducing the number of setups needed to produce those parts.
6:51
Once the build box has been created, our technician, Alexis, can load the file and begin the print.
Metal Binder Jet Printing Process
7:48
Now we will take a look at the metal binder jet process in our 25 Pro.
This build contains three sets of five unique designs for a total of 15 parts. This print allows us to create and test design iterations simultaneously.
8:20
Now we will walk through the steps of the metal binder jet process.
8:26
In the first step, a heated lamp moves over the face of the powder to dry the binder and maintain the temperature of the print bed.
8:43
Next, powder is dispensed onto the print bed and rolled into a flat layer.
8:53
Finally, the printhead travels over the print bed, dispensing binder over the part geometries.
9:19
Each layer of this print is 50 microns thick. By combining many of these two-dimensional layers, we are able to create unique and precise three-dimensional geometries.
9:36
In our 25 Pro, it takes approximately 40 seconds to complete a layer.
Curing and Depowdering
9:51
After the print is complete, a curing operation is required to provide enough green strength for the parts to be handled.
This operation is achieved by heating the binder to a couple hundred degrees Celsius.
10:05
Here, our technician Alexis is loading the finished print into the cure oven.
10:21
After curing, the parts have enough green strength that they can be handled.
This leads us into our next operation: depowdering.
10:31
During depowdering, it is necessary to remove all loose powder from the parts so that it is not sintered into the final component.
This is currently done using brushes and compressed air.
10:45
As can be seen, this is a labor-intensive operation.
10:50
DSB is looking to leverage its internal automation group to automate this process, both to decrease labor requirements and increase the quality of the operation.
11:03
Here is an example of our internal automation group leveraging automation for part handling.
Sintering Metal Binder Jet Parts
11:18
Once the part is depowdered, it is ready for sintering.
11:22
An important consideration in metal binder jet design is sinter shrinkage. As can be seen, the ready-to-sinter green part is roughly 20% larger than the sintered part.
This size change is similar to what is seen in metal injection molding.
11:45
For our sintering furnaces, we have our previously discussed Elnik vacuum furnace for prototype and production development.
We’ve been utilizing this furnace to test materials and benchmark sinter performance.
12:06
A key competency of DSB Technologies is high-temperature sintering. The furnace shown is on one of our press-sinter lines and provides us with a means to high-temperature sinter in a continuous process.
12:20
We are looking to leverage our in-house experience and the largest capacity of high-temperature sintering in North America to industrialize the sintering of metal binder jet components.
Post-Sintering Manufacturing
12:38
After the part is sintered to its desired material properties, it can be shipped to the customer or proceed to additional manufacturing if required.
12:49
At our one-stop manufacturing facility, DSB is able to provide additional post-sintering manufacturing.
We have an extensive secondary machining department capable of milling, turning, tapping, and much more.
13:06
If other specific post-sintering operations are needed, we can develop them in-house.
In this example, we can see our custom-built brushing cell.
13:17
In the cell, the robot precisely manipulates the part to break edges, add curvature, and meet surface finish requirements.
This is one of many examples of solutions developed by our internal automation team to meet customer post-sintering needs.
Part Design Recap
13:47
To recap, we started with a customer design of a urea flange.
We then redesigned that part to optimize it for metal binder jetting.
14:02
We lightweighted the part by removing unnecessary material while still maintaining the key features of the component.
14:12
We still have the counterbore on the top, the three lightweighted flanges, and finally, the cone on the bottom.
Metal Binder Jetting Process Recap
14:29
To recap the process, we started with the design of the part, which we optimized for metal binder jetting. The design was then transferred to the printer via USB.
14:40
During printing, individual layers of powder and binder were deposited until we produced a three-dimensional part.
14:48
After printing, the part was moved to the cure oven so it could achieve the desired green strength needed for handling.
14:57
Once curing was complete, the parts were depowdered to remove any loose powder.
15:03
Finally, the parts were sintered to achieve their desired material properties.
15:11
Together, metal binder jetting accelerates production development, allowing DSB to proceed from a design to an initial sintered part in about a week.
That’s what makes DSB your one-stop metal binder jetting manufacturing partner.