Using adaptive slicing method and variable binder amount algorithm in binder jetting

Abstract

Purpose

Binder jetting is one of the essential additive manufacturing methods because it is cost-effective, has no thermal stress problems and has a wide range of different materials. Using binder jetting technology in the industry is becoming more common recently. However, it has disadvantages compared to traditional manufacturing methods regarding speed. This study aims to increase the manufacturing speed of binder jetting.

Design/methodology/approach

This study used adaptive slicing to increase the manufacturing speed of binder jetting. In addition, a variable binder amount algorithm has been developed to use adaptive slicing efficiently. Quarter-spherical shaped samples were manufactured using a variable binder amount algorithm and adaptive slicing method.

Findings

Samples were sintered at 1250°C for 2 h with 10°C/min heating and cooling ramp. Scanning electron microscope analysis, surface roughness tests, and density calculations were done. According to the results obtained from the analyzes, similar surface quality is achieved by using 38% fewer layers than uniform slicing.

Research limitations/implications

More work is needed to implement adaptive slicing to binder jetting. Because the software of commercial printers is very difficult to modify, an open-source printer was used. For this reason, it can be challenging to produce perfect samples. However, a good start has been made in this area.

Originality/value

To the best of the authors’ knowledge, the actual use of adaptive slicing in binder jetting was applied for the first time in this study. A variable binder amount algorithm has been developed to implement adaptive slicing in binder jetting.

Citation

Baş, H., Yapıcı, F. and İnanç, İ. (2023), "Using adaptive slicing method and variable binder amount algorithm in binder jetting", Rapid Prototyping Journal, Vol. 29 No. 8, pp. 1730-1741. https://doi.org/10.1108/RPJ-11-2022-0372