To fill the gap in a rational strategy for materials selection and process optimization, the effect of 3D binder jetting on the packing density and pore structure of AISI 316L SS powders with a wide range of particle sizes (d = 5–60 µm) and deposition thicknesses <InlineEquation ID="IEq1"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="43579_2025_731_Article_IEq1.gif" Format="GIF" Height="19" Rendition="HTML" Resolution="72" Type="Linedraw" Width="115" /> </InlineMediaObject> <EquationSource Format="TEX">$\left( {1 \le H/d \le 10} \right)$</EquationSource> <EquationSource Format="MATHML"><math> <mfenced close=")" open="("> <mrow> <mn>1</mn> <mo>≤</mo> <mi>H</mi> <mo stretchy="false">/</mo> <mi>d</mi> <mo>≤</mo> <mn>10</mn> </mrow> </mfenced> </math></EquationSource> </InlineEquation> were investigated. We introduce a new dimensionless parameter, <InlineEquation ID="IEq2"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="43579_2025_731_Article_IEq2.gif" Format="GIF" Height="31" Rendition="HTML" Resolution="72" Type="Linedraw" Width="89" /> </InlineMediaObject> <EquationSource Format="TEX">$\varphi = \frac{{1 - \left( {d/H} \right)^{2} }}{{1 + \left( {d/H} \right)}}$</EquationSource> <EquationSource Format="MATHML"><math> <mrow> <mi>φ</mi> <mo>=</mo> <mfrac> <mrow> <mn>1</mn> <mo>-</mo> <msup> <mfenced close=")" open="("> <mrow> <mi>d</mi> <mo stretchy="false">/</mo> <mi>H</mi> </mrow> </mfenced> <mn>2</mn> </msup> </mrow> <mrow> <mn>1</mn> <mo>+</mo> <mfenced close=")" open="("> <mrow> <mi>d</mi> <mo stretchy="false">/</mo> <mi>H</mi> </mrow> </mfenced> </mrow> </mfrac> </mrow> </math></EquationSource> </InlineEquation>, and demonstrate that the packing density and binder-induced pores abruptly varies with <InlineEquation ID="IEq3"> <InlineMediaObject> <ImageObject Color="BlackWhite" FileRef="43579_2025_731_Article_IEq3.gif" Format="GIF" Height="12" Rendition="HTML" Resolution="72" Type="Linedraw" Width="16" /> </InlineMediaObject> <EquationSource Format="TEX">$\varphi$</EquationSource> <EquationSource Format="MATHML"><math> <mi>φ</mi> </math></EquationSource> </InlineEquation> in a semi-log scale and d−2, respectively. In light of the mechanistic understanding of the transient behavior, the optimum d/H value to attain dense and homogeneous parts is proposed. Graphical abstract

Mastering binder jet 3D printing of 316L stainless steel: A descriptive model approach to particle size and deposition thickness

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2025年5月19日

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A. Simchi,
B. Barthel,
S. B. Hein,
L. Reineke,
D. Hosseini

摘要

To fill the gap in a rational strategy for materials selection and process optimization, the effect of 3D binder jetting on the packing density and pore structure of AISI 316L SS powders with a wide range of particle sizes (d = 5–60 µm) and deposition thicknesses $\left( {1 \le H/d \le 10} \right)$ $(1 \leq H / d \leq 10)$ were investigated. We introduce a new dimensionless parameter, $\varphi = \frac{{1 - \left( {d/H} \right)^{2} }}{{1 + \left( {d/H} \right)}}$ $φ = \frac{1 - {(d / H)}^{2}}{1 + (d / H)}$ , and demonstrate that the packing density and binder-induced pores abruptly varies with $\varphi$ $φ$ in a semi-log scale and d⁻², respectively. In light of the mechanistic understanding of the transient behavior, the optimum d/H value to attain dense and homogeneous parts is proposed.

Graphical abstract