binder jetting additive manufacturing of ceramic materials · 10/12/2017 · •binder jetting is...
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Binder Jetting Additive Manufacturing of Ceramic Materials
American Ceramic Society Short Course Jesse Blacker, Product Development Manager & Principal Investigator
10.12.2017
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
Presentation Overview
1. Introduction to Binder Jetting AM
2. Binder Jetting Machines for Ceramics
3. Ceramic Materials & Applications in Binder Jetting AM
4. Summary
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Binder Jetting Additive Manufacturing
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
1. Introduction to Binder Jetting AM
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Comparison to other AM Technology
* Additive manufacturing categories as classified by ASTM
Binder Jetting Benefits • Machine Size • Part Size • Machine Speed • Low cost • Broad portfolio of materials
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
1. Introduction to Binder Jetting AM
Raw Material
(Powder) Forming
High Temperature
Processing Finishing Characterization
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Ceramic Part Manufacturing Process Flow
Powder Recoating
Digital Data Feed
Binder Deposition
Binder Jetting is an alternative shape forming process for ceramic material manufacturing.
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
1. Introduction to Binder Jetting AM
Powder & Recoating
Digital Model / Data
Binder Deposition
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Components of Binder Jetting Process
3D Printed Glass Artwork produced with Binder Jetting AM
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
1. Introduction to Binder Jetting AM
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Powder & Recoating
Standard dispenser for free-flowing, large diameter powders (d50 >25 micron)
Modified dispenser and leveling systems for poor-flowing, small diameter powders (d50 < 25 micron)
Representative only
• Challenge: • Ceramic powders suitable for sintering (high surface area, small particle size) don’t flow or spread well,
which makes thin layer and voxel creation difficult. • Ceramic powders suitable for printing (historically) don’t sinter well due to large particle sizes.
• The push for enabling direct printing of technical ceramics with binder jetting is in creation of new recoater designs to print powders with small d50 PS, bi-modal PSD, or large PSD
Smooth layer of sinterable, poor flowing, Alumina powder using experimental recoater
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
1. Introduction to Binder Jetting AM
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Binder Deposition
• Surface finish is driven by: • Binder Droplet Size & Spacing
• Layer Thickness
• Powder Size
Piezo-wall
Drop Generator Chamber
Binder
Drop generator chamber is displaced to eject a drop.
Droplet Volume (pL) 80 30 10
DPI 450 900 1200
Innovent™ M-Flex® M-Print™
Print Nozzles 256 1024 1200
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
1. Introduction to Binder Jetting AM
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Overall Process
1. CAD model 2. Part is printed
4. Part is depowdered 5. Part is processed through heat
cycle
6. Part is completed in less than 3
days
3. Part is cured
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
1. Introduction to Binder Jetting AM
9
Video
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
2. Binder Jetting Machines
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Innovent™ - Ceramic Printing Machine – Designed for Research & Development
Innovent™ Description
Build Size 160 x 65 x 65 mm
Build Speed 30-60 sec / layer
Min Layer 50 mm
Powder Size* > 5 micron
Data Interface STL
* Powder dependent
Test coupons
Recoater and Build Box
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
2. Binder Jetting Machines
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M-Flex® - Ceramic Printing Machine
Innovent™ Description
Build Size 400 x 250 x 250 mm
Build Speed 30-60 sec / layer
Min. Layer 50 mm
Powder Size* > 15 micron
Data Interface STL
* Powder dependent Printed SiC Optical Structure
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
2. Binder Jetting Machines
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M-Print™ - Ceramic Printing Machine
Innovent™ Description
Build Size 800 x 500 x 400 mm
Build Speed 60 sec / layer
Min. Layer 150 mm
Powder Size* > 60 micron
Data Interface STL
* Powder dependent
Printed Ceramic Mandrel
Printed Ceramic Castle
Ceramic (Mullite) Parts from ExOne M-Print
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
3. Ceramic Materials & Applications Binder Jetting Closely Related to Powder Metallurgy / Materials
Bonded
Partially Sintered
Highly Sintered
Possible Product Forms
Infiltrated
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
3. Ceramic Materials & Applications
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Tungsten Carbide
Global Tungsten & Powders Towanda, PA
AM WC701 powder
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
3. Ceramic Materials & Applications
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Reaction Bonded Silicon Carbide
https://www.sglgroup.com/cms/_common/downloads/innovation/future-carbon-technologies/CARBOPRINT_additiv_manufacturing_with_carbons_e.pdf
Carbon Print Material & Si Infiltration / Reaction SiC Print Material & Si Infiltration / Reaction
Program Goal: Develop 3DP capability for SiC optical
support structures, meeting MDA material property
requirements.
Si Infiltrated SiC SiC optical structure 3D printed preform
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
3. Ceramic Materials & Applications
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Aluminum Oxide
ExOne® 3D Printed Alumina Sintering Setters
• Designed to prevent distortion during sintering process of MIM
and Metal AM Parts
• Significantly reduce lead times for custom geometry setters
• Printed in >99% purity alumina
High Density Alumina – University of Texas El Paso (UTEP)
Additive Manufacturing of High-Performance Ceramics – ACerS Short Course
4. Summary
• Binder Jetting has inherent advantages for Additive Manufacturing of Ceramics: • Print Speed, Print Size, Material Choices & Flexibility
• Binder Jetting has inherent challenges for Additive Manufacturing of Ceramics: • Limitations on powder size capabilities
• Knowledge gaps in thermal processing of AM pre-forms
• Binder Jetting with today’s state-of-the-art capabilities has application in many ceramic materials markets: • Reaction Bonded / Siliconized Silicon Carbide (SiC) for Optics, Automotive, Chemical, and High-temperature Material
industries
• Tungsten Carbide / Cobalt (WC/Co) for wear parts and cutting tool industries
• Oxide based ceramics for filters, electronics packaging, etc.
• Binder Jetting is continuing to grow, and future machine enhancements for printing small particle size, sinterable ceramic powders will continue to create broader adoption.
• Published material property characterization data from large industrial players will also drive adoption throughout the industry.
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Binder Jetting for Ceramic Materials
Thank You! Jesse Blacker
www.exone.com
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