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<p>Among additive manufacturing (AM) methods, extrusion-based AM (EAM) stands out for its design flexibility and material efficiency, gaining attention for printing objects without requiring high temperature during deposition. This study investigates the fabrication of aluminum and aluminum alloy components using an extrusion-based 3D printing approach, employing a butanol-based paste formulation. The butanol binder minimizes oxidation, improves rheological properties, and ensures smooth extrusion and shape retention prior to post-processing. Printed structures undergo subsequent debinding and sintering to remove the gel part and enhance densification. An optimization of the debinding and sintering cycle is also investigated. Finally, the printing of aluminum–silicon alloys further improves sample densification using liquid-phase sintering. The findings demonstrate butanol-based paste extrusion as a promising method for manufacturing complex aluminum components, with potential applications in aerospace, automotive, and industrial sectors.</p>

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3D printing of porous aluminum-based materials via extrusion additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年6月12日

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  • Laurent Cuzacq,
  • Jean-Louis Bobet,
  • Sébastien Fourcade,
  • Yongfeng Lu,
  • Jean-Luc Battaglia,
  • Jean-François Silvain

摘要

Among additive manufacturing (AM) methods, extrusion-based AM (EAM) stands out for its design flexibility and material efficiency, gaining attention for printing objects without requiring high temperature during deposition. This study investigates the fabrication of aluminum and aluminum alloy components using an extrusion-based 3D printing approach, employing a butanol-based paste formulation. The butanol binder minimizes oxidation, improves rheological properties, and ensures smooth extrusion and shape retention prior to post-processing. Printed structures undergo subsequent debinding and sintering to remove the gel part and enhance densification. An optimization of the debinding and sintering cycle is also investigated. Finally, the printing of aluminum–silicon alloys further improves sample densification using liquid-phase sintering. The findings demonstrate butanol-based paste extrusion as a promising method for manufacturing complex aluminum components, with potential applications in aerospace, automotive, and industrial sectors.