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<p>This study provides a feasibility-level assessment of a geometry-driven co-sintering strategy for metal Binder Jetting (BJT) to enable modular fabrication beyond conventional build-volume limitations. Complementary green parts in 17-4PH stainless steel, featuring interlocking geometries, were printed separately, manually assembled in the green state, and subsequently co-sintered without external pressure to avoid potential damage. Three prismatic joint configurations (box, dovetail, and pyramidal) and three cylindrical configurations (threaded M10, threaded M14, and conical) were systematically analyzed as a function of the nominal interface offset. Dimensional measurements and local split thickness analysis revealed that the residual interface opening after sintering is consistently lower than the imposed design offset, indicating shrinkage-assisted partial gap closure during densification. The evolution of the split distribution demonstrated geometry-dependent behavior: interlocking prismatic joints were more sensitive to assembly misalignment and local constraint effects, whereas axisymmetric cylindrical configurations exhibited more uniform shrinkage accommodation. The approach combines mechanical interlocking in the green state with potential metallurgical bonding during sintering, providing a framework for modular BJT assemblies and offering a promising pathway to simplifying the depowdering phase of complex parts and overcoming build-size limitations. While mechanical characterization of the joints is required to assess structural load-bearing capability, the study establishes the geometrical and process foundations necessary for controlled co-sintered assemblies. Future optimization should assess the repeatability of the junctions produced considering the intrinsic variability of the BJT process.</p>

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Modular Binder Jetting via geometry-driven interlocking and co-sintering

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年7月14日

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  • Sara Candidori,
  • Marco Mariani,
  • Lorenzo Cocchi,
  • Andrea Lucchini Huspek,
  • Massimiliano Bestetti,
  • Roberto Viganò,
  • Serena Graziosi,
  • Nora Lecis

摘要

This study provides a feasibility-level assessment of a geometry-driven co-sintering strategy for metal Binder Jetting (BJT) to enable modular fabrication beyond conventional build-volume limitations. Complementary green parts in 17-4PH stainless steel, featuring interlocking geometries, were printed separately, manually assembled in the green state, and subsequently co-sintered without external pressure to avoid potential damage. Three prismatic joint configurations (box, dovetail, and pyramidal) and three cylindrical configurations (threaded M10, threaded M14, and conical) were systematically analyzed as a function of the nominal interface offset. Dimensional measurements and local split thickness analysis revealed that the residual interface opening after sintering is consistently lower than the imposed design offset, indicating shrinkage-assisted partial gap closure during densification. The evolution of the split distribution demonstrated geometry-dependent behavior: interlocking prismatic joints were more sensitive to assembly misalignment and local constraint effects, whereas axisymmetric cylindrical configurations exhibited more uniform shrinkage accommodation. The approach combines mechanical interlocking in the green state with potential metallurgical bonding during sintering, providing a framework for modular BJT assemblies and offering a promising pathway to simplifying the depowdering phase of complex parts and overcoming build-size limitations. While mechanical characterization of the joints is required to assess structural load-bearing capability, the study establishes the geometrical and process foundations necessary for controlled co-sintered assemblies. Future optimization should assess the repeatability of the junctions produced considering the intrinsic variability of the BJT process.