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<p>In Sinter-based additive manufacturing methods, such as Binder Jet Printing, achieving effective thermal debinding is critical for minimizing carbon pick-up in sintered parts, particularly for reactive metals like titanium. This study investigates how particle packing, influenced by particle size distribution (PSD), affects binder distribution and subsequent debinding effectiveness. Using Discrete Element Method (DEM) modeling informed by SEM-based particle size measurements, we simulated realistic powder packings to evaluate two key parameters: the coordination number (CN), representing particle contact density, and the active surface area-to-volume (ATV) ratio of binder necks, derived from modeled particle contacts. Experimental validation involved carbon analysis of printed and sintered Ti parts with varying PSDs but constant binder volume. Surprisingly, the BET specific surface area (BET SSA) of the powder showed no direct correlations with carbon pick-up, whereas both CN and ATV ratios strongly influenced debinding outcomes. Optimized powder blends identified by DEM modeling picked-up 40% less carbon than unoptimized blends. These results demonstrate that improved powder packing not only enhances green strength but also significantly improves debinding effectiveness by maximizing binder distribution and reactivity. This approach provides a predictive, cost-efficient strategy for optimizing powder blends in polymer-bonded metal powder additive manufacturing systems.</p>

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Effects of particle packing on the debinding effectiveness in 3D printed polymer-bonded metal powder parts

  • 期刊论文

  • 发表日期：

    2025年12月18日

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  • Nathan Jump,
  • Pei Sun,
  • Zhigang Fang

摘要

In Sinter-based additive manufacturing methods, such as Binder Jet Printing, achieving effective thermal debinding is critical for minimizing carbon pick-up in sintered parts, particularly for reactive metals like titanium. This study investigates how particle packing, influenced by particle size distribution (PSD), affects binder distribution and subsequent debinding effectiveness. Using Discrete Element Method (DEM) modeling informed by SEM-based particle size measurements, we simulated realistic powder packings to evaluate two key parameters: the coordination number (CN), representing particle contact density, and the active surface area-to-volume (ATV) ratio of binder necks, derived from modeled particle contacts. Experimental validation involved carbon analysis of printed and sintered Ti parts with varying PSDs but constant binder volume. Surprisingly, the BET specific surface area (BET SSA) of the powder showed no direct correlations with carbon pick-up, whereas both CN and ATV ratios strongly influenced debinding outcomes. Optimized powder blends identified by DEM modeling picked-up 40% less carbon than unoptimized blends. These results demonstrate that improved powder packing not only enhances green strength but also significantly improves debinding effectiveness by maximizing binder distribution and reactivity. This approach provides a predictive, cost-efficient strategy for optimizing powder blends in polymer-bonded metal powder additive manufacturing systems.