Powder-Binder Interaction in Binder Jetting Process: A Simulation Study on Bimodal Powders

Binder Jetting (BJT) is a room-temperature powder-bed additive manufacturing process suitable for a wide range of materials such as bioceramics, sand, metals, and polymers. In this process, powder-binder interaction, which is influenced by the powder bed packing density during the printing process, has a major impact on the overall part quality. Although few recent studies have explored the modeling of the binder-jetting process, they are not realistic (e.g., 200 % larger droplet size when compared to the actual process). This study is the first to report a systematic study into the powder-binder interactions for bimodal powders with actual binder-jetting conditions across a wide range of packing densities and binder-jetting conditions. This integrated Discrete Element Modeling (DEM - powder spreading) – VOF (Volume of Fluid - binder interaction) study analyzed the powder-binder interaction in terms of: penetration depth, spreading time, and area per droplet on the powder bed. It was observed that an increase in droplet velocity resulted in deeper penetration (5.4%) of the binder but reduced the area of spread (20.8%) across packing densities. In addition, for a given droplet size and packing density, an increase in droplet velocity resulted in a shorter spreading time (27.3%). Findings from this study provide a new understanding of the temporospatial characteristics of the binder-powder interaction, which helps in identifying optimal printing parameters for a bimodal powder feedstock.

Advisor: Guha Manogharan; Department of Mechanical Engineering; Department of Industrial and Manufacturing Engineering; The Pennsylvania State University; University Park, PA

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Work Title Powder-Binder Interaction in Binder Jetting Process: A Simulation Study on Bimodal Powders
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Penn State
Creators
  1. Kazi Safowan Shahed
  2. Guha Manogharan
Keyword
  1. Additive manufacturing
  2. Binder jetting
  3. Bimodal powder
  4. Powder-binder interaction
  5. Simulation
License In Copyright (Rights Reserved)
Work Type Conference Proceeding
Publisher
  1. Proceedings of the ASME 2023 18th International Manufacturing Science and Engineering Conference. Volume 1: Additive Manufacturing; Advanced Materials Manufacturing; Biomanufacturing; Life Cycle Engineering
Publication Date September 28, 2023
Publisher Identifier (DOI)
  1. https://doi.org/10.1115/MSEC2023-104366
Deposited November 04, 2023

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Version 1
published

  • Created
  • Updated
  • Added MSEC2023-104366_Kazi.pdf
  • Added Creator Kazi Safowan Shahed
  • Updated License Show Changes
    License
    • https://rightsstatements.org/page/InC/1.0/
  • Updated Description Show Changes
    Description
    • Binder Jetting (BJT) is a room-temperature powder-bed
    • additive manufacturing process suitable for a wide range of
    • materials such as bioceramics, sand, metals, and polymers. In
    • this process, powder-binder interaction, which is influenced by
    • the powder bed packing density during the printing process, has
    • a major impact on the overall part quality. Although few recent
    • studies have explored the modeling of the binder-jetting process,
    • they are not realistic (e.g., 200 % larger droplet size when
    • compared to the actual process). This study is the first to report
    • a systematic study into the powder-binder interactions for
    • bimodal powders with actual binder-jetting conditions across a
    • wide range of packing densities and binder-jetting conditions.
    • This integrated Discrete Element Modeling (DEM - powder
    • spreading) – VOF (Volume of Fluid - binder interaction) study
    • analyzed the powder-binder interaction in terms of: penetration
    • depth, spreading time, and area per droplet on the powder bed.
    • It was observed that an increase in droplet velocity resulted in
    • deeper penetration (5.4%) of the binder but reduced the area of
    • spread (20.8%) across packing densities. In addition, for a given
    • droplet size and packing density, an increase in droplet velocity
    • resulted in a shorter spreading time (27.3%). Findings from this
    • study provide a new understanding of the temporospatial
    • characteristics of the binder-powder interaction, which helps in
    • identifying optimal printing parameters for a bimodal powder
    • feedstock.
    • Advisor:
    • Guha Manogharan
    • Department of Mechanical Engineering
    • Department of Industrial and Manufacturing Engineering
    • The Pennsylvania State University
    • University Park, PA
  • Updated Publisher Identifier (DOI) Show Changes
    Publisher Identifier (DOI)
    • https://doi.org/10.1115/MSEC2023-104366
  • Published
  • Updated

Version 2
published

  • Created
  • Updated Description Show Changes
    Description
    • Binder Jetting (BJT) is a room-temperature powder-bed
    • additive manufacturing process suitable for a wide range of
    • materials such as bioceramics, sand, metals, and polymers. In
    • this process, powder-binder interaction, which is influenced by
    • the powder bed packing density during the printing process, has
    • a major impact on the overall part quality. Although few recent
    • studies have explored the modeling of the binder-jetting process,
    • they are not realistic (e.g., 200 % larger droplet size when
    • compared to the actual process). This study is the first to report
    • a systematic study into the powder-binder interactions for
    • bimodal powders with actual binder-jetting conditions across a
    • wide range of packing densities and binder-jetting conditions.
    • This integrated Discrete Element Modeling (DEM - powder
    • spreading) – VOF (Volume of Fluid - binder interaction) study
    • analyzed the powder-binder interaction in terms of: penetration
    • depth, spreading time, and area per droplet on the powder bed.
    • It was observed that an increase in droplet velocity resulted in
    • deeper penetration (5.4%) of the binder but reduced the area of
    • spread (20.8%) across packing densities. In addition, for a given
    • droplet size and packing density, an increase in droplet velocity
    • resulted in a shorter spreading time (27.3%). Findings from this
    • study provide a new understanding of the temporospatial
    • characteristics of the binder-powder interaction, which helps in
    • identifying optimal printing parameters for a bimodal powder
    • feedstock.
    • Advisor:
    • Guha Manogharan
    • Department of Mechanical Engineering
    • Department of Industrial and Manufacturing Engineering
    • The Pennsylvania State University
    • Guha Manogharan;
    • Department of Mechanical Engineering;
    • Department of Industrial and Manufacturing Engineering;
    • The Pennsylvania State University;
    • University Park, PA
  • Published
  • Updated Keyword, Publisher, Publication Date Show Changes
    Keyword
    • dditive manufacturing, binder jetting, bimodal powder, powder-binder interaction, simulation
    • Additive manufacturing, Binder jetting, Bimodal powder, Powder-binder interaction, Simulation
    Publisher
    • Proceedings of the ASME 2023 18th International Manufacturing Science and Engineering Conference. Volume 1: Additive Manufacturing; Advanced Materials Manufacturing; Biomanufacturing; Life Cycle Engineering
    Publication Date
    • 2023
    • 2023-09-28
  • Added Creator Guha Manogharan
  • Updated