Process parameters optimization for improving surface quality and manufacturing accuracy of binder jetting additive manufacturing process

Binder jetting (BJ) process is an additive manufacturing (AM) process in which powder materials are selectively joined by binder materials. Products can be manufactured layer-by-layer directly from three-dimensional model data. The quality properties of the products fabricated by the BJ AM process are significantly affected by the process parameters. To improve the product quality, the optimal process parameters need to be identified and controlled. This research works with the 420 stainless steel powder material.

This study focuses on four key printing parameters and two end-product quality properties. Sixteen groups of orthogonal experiment designed by the Taguchi method are conducted, and then the results are converted to signal-to-noise ratios and analyzed by analysis of variance.

Five sets of optimal parameters are concluded and verified by four group confirmation tests. Finally, by taking the optimal parameters, the end-product quality properties are significantly improved.

These optimal parameters can be used as a guideline for selecting proper printing parameters in BJ to achieve the desired properties and help to improve the entire BJ process ability.