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Removal of Stair-Step Effects in Binder Jetting Additive Manufacturing Using Grayscale and Dithering-Based Droplet

Christoph Hartmann¹, Lucas van den Bosch¹, Johannes Spiegel¹

¹Fraunhofer Institute for Casting, Composite and Processing Technology IGCV, Lichtenbergstr. 15, 85748 Garching, Germany.

Materials (Basel, Switzerland)

|June 10, 2022

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Characterization of Slurry-Cast Layer Compounds for 3D Printing of High Strength Casting Cores.

Materials (Basel, Switzerland)·2021

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This study introduces a novel binder jetting method to eliminate the stair-step effect in 3D printed parts. By precisely controlling binder saturation, this process enhances surface quality without post-processing.

Area of Science:

Additive Manufacturing
Materials Science
Surface Engineering

Background:

Binder jetting is a layer-based additive manufacturing technique.
Current binder jetting processes suffer from surface roughness, notably the stair-step effect, limiting part quality.
Post-processing is typically required to address surface imperfections.

Purpose of the Study:

To present a novel method for eliminating the stair-step effect in binder jetting.
To improve the surface quality of binder jetted parts intrinsically.
To enable high-quality casting molds and cores using binder jetting.

Main Methods:

Developed a binder jetting process modification to control binder saturation in individual voxel volumes.
Utilized droplet size variation and dithering to manage binder migration.

Keywords:

3D printing additive manufacturing binder jetting casting dithering finishing grayscale sand printing stair-steps surface quality

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Applied the method to silica sand with an organic binder for casting applications.

Main Results:

Successfully eliminated the stair-step effect in binder jetted parts.
Demonstrated improved surface quality without the need for post-processing.
Validated the effectiveness of the controlled binder saturation approach.

Conclusions:

The developed method offers a viable solution to a long-standing challenge in binder jetting.
Precise control over binder saturation can significantly enhance part surface quality.
This research opens new avenues for high-fidelity binder jetting applications, particularly in casting.