A finned-riser design to avoid the capillarity effect in multi-jet fusion technology

Abstract

Purpose

Multi-jet fusion (MJF) process is based on a polymeric powder bed that is heated and irradiated by infra-red lamps. The layer under construction is jetted with inks to provide the desired heat management conditions for selective melting. Depending on several process variables, manufactured parts can exhibit lifting of the borders of the top surface of the shape under construction. This phenomenon is related to the capillarity effect. As a result, the top surface of MJF-manufactured parts can present a peculiar convex shape. This study aims to propose a solution that instead induces the capillarity effect outside of the part under construction.

Design/methodology/approach

A specific design is developed to avoid the capillarity effect in MJF. It is based on an analytical model that was previously developed by the authors to estimate the shape and extent of the capillary on top surfaces of benchmark components. The proposed methodology is established by the predicted calculation of maximum values of capillarity rise and length, and safety factors. A fin-shaped geometry is designed to avoid the capillarity effect. An experimental campaign is implemented to verify the effectiveness of the proposed solution. Prototypes are manufactured by an HP MultiJet 4200 in the original design and the so-called finned-riser design, by adding a well-dimensioned appendage on the top surface to shift the capillarity effect outside the border of the part under construction. Measurements are done by a CAM2 ScanArm contactless measuring system to achieve the real shape of top surfaces. Geomagic Control X software by 3D systems is used to evaluate the quality of measured surfaces in comparison with the expected geometry of the top plane of the benchmark.

Findings

The investigated approach involves adding an auxiliary finned-shape appendage, which acts similarly to the risers in foundry technology, to the top surface of the part that is being produced by MJF technology. The procedure and rules for determining the dimensions of the fin are established based on physical considerations and process modelling. The method is then applied to a prototype part, which is designed to highlight the effectiveness of the finned-riser design for improving the dimensional accuracy of the top surfaces of products manufactured by the MJF process. Experimental measurements of top surfaces of the original benchmark are compared to the same ones in the case of the finned-riser benchmark. Reported results are satisfactory, and the capillary effect occurred in the fins outside the border edges of the part. Further developments are planned to extend the proposed design.

Originality/value

MJF technology is attracting large interest from manufacturers to produce mass customised products. The quality of manufactured parts could be affected by peculiar defects related to process parameters. The present work aims to show a method to avoid the capillarity effect. It is based on an original analytical model developed by the authors and implemented successfully in the case of a benchmark geometry.

Citation

Mele, M., Campana, G. and Monti, G.L. (2021), "A finned-riser design to avoid the capillarity effect in multi-jet fusion technology", Rapid Prototyping Journal, Vol. 27 No. 1, pp. 1-12. https://doi.org/10.1108/RPJ-01-2020-0020