Process Parameter Optimization of Extrusion-Based 3D Metal Printing Utilizing PW-LDPE-SA Binder System.

Area of Science:

• Materials Science
• Additive Manufacturing
• Metallurgy

Background:

• Extrusion-based 3D printing is advancing for metal fabrication, enabling complex parts for electronics and composites.
• Optimizing printing and sintering parameters is crucial for achieving desired material properties.

Purpose of the Study:

• To optimize critical parameters for extrusion-based 3D printing of copper powder.
• To investigate the influence of process parameters on the mechanical properties of green and sintered samples.

Main Methods:

• Experiments were conducted using a melting extrusion printer with copper powder and a thermoplastic binder (paraffin wax, low density polyethylene, stearic acid).
• Orthogonal design was employed to optimize printing and sintering parameters.
• Homogeneity, rheological behavior, green sample strength, and sintered sample hardness were analyzed.

Main Results:

• For green samples, infill degree, raster angle, and layer thickness significantly influenced ultimate tensile strength.
• Sintering temperature was the primary factor affecting hardness, followed by holding time and heating rate.
• The highest achieved hardness of sintered samples closely matched that of commercially pure copper.

Conclusions:

• Extrusion-based 3D printing is a viable and promising strategy for metal material fabrication.
• This method offers advantages in cost, efficiency, and simplicity compared to traditional manufacturing approaches.
• Further optimization can lead to high-performance metal components through additive manufacturing.