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<p>In binder jetting additive manufacturing, sintering-induced shrinkage and deformation significantly influence final part accuracy. This study presents a novel, cost-effective in-process monitoring approach capable of capturing dimensional change in larger components, addressing the limitations of traditional dilatometry, typically restricted to small specimens. Binder jetted green parts with an initial relative density of ~ 55% were sintered at 1400°C, achieving final densities exceeding 99.9% and exhibiting anisotropic shrinkage. Real-time imaging during sintering was employed to quantify strain development and estimate shear and bulk viscosities by combining grain size measurements. The modeling framework is grounded in the continuum sintering theory developed by Skorohod and Olevsky. Finite element method (FEM) simulations were also conducted to predict shrinkage behavior, validate experimental trends, and further assess the impact of anisotropic material response during sintering. The study establishes a direct correlation between pore evolution, thermal conditions, and directional shrinkage. These findings enhance the understanding of anisotropic sintering behavior in binder jetted components and contribute to predictive modeling capabilities for improved dimensional control in sinter-based additive manufacturing processes.</p>

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Anisotropic Shrinkage of Binder Jetted Components: Simulation and In Situ Experimental Measurement for Validation

  • 期刊论文

  • 发表日期：

    2025年9月16日

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  • Matin Vafaei,
  • Zhifang Deng,
  • Dayue Jiang,
  • Mohammad Jamalkhani,
  • Fuda Ning,
  • Amir Mostafaei

摘要

In binder jetting additive manufacturing, sintering-induced shrinkage and deformation significantly influence final part accuracy. This study presents a novel, cost-effective in-process monitoring approach capable of capturing dimensional change in larger components, addressing the limitations of traditional dilatometry, typically restricted to small specimens. Binder jetted green parts with an initial relative density of ~ 55% were sintered at 1400°C, achieving final densities exceeding 99.9% and exhibiting anisotropic shrinkage. Real-time imaging during sintering was employed to quantify strain development and estimate shear and bulk viscosities by combining grain size measurements. The modeling framework is grounded in the continuum sintering theory developed by Skorohod and Olevsky. Finite element method (FEM) simulations were also conducted to predict shrinkage behavior, validate experimental trends, and further assess the impact of anisotropic material response during sintering. The study establishes a direct correlation between pore evolution, thermal conditions, and directional shrinkage. These findings enhance the understanding of anisotropic sintering behavior in binder jetted components and contribute to predictive modeling capabilities for improved dimensional control in sinter-based additive manufacturing processes.