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High-Resolution Multi-Metal 3D Printing: A Novel Approach Using Binder Jet Printing and Selecting Laser Melting in Powder Bed Fusion

Beng-Loon Aw^1,*

1 A*STAR Research Entities Singapore (ARES), Singapore Institute of Manufacturing Technology (SIMTech), 5 Cleantech Loop, Singapore, S636732, Singapore

* Corresponding Author: Beng-Loon Aw. Email: -star.edu.sg

The International Conference on Computational & Experimental Engineering and Sciences 2024, 32(1), 1-1. https://doi.org/10.32604/icces.2024.011990

Abstract

This study introduces a novel method that combines Binder Jet Printing (BJP) and Selective Laser Melting (SLM) techniques to achieve unprecedented high-speed and high-resolution 3D printing of fine metal powders in Laser Powder Bed Fusion (LPBF). Our approach comfortably attains a resolution of 0.2 mm, enabling the selective deposition of fine powder (D50: 30 µm) made from multiple materials within a single print layer. We demonstrate the capability of this technique through the printing of a composite structure composed of copper alloy and 18Ni300 Maraging tool steel, showcasing its potential for fast-cooling tooling applications. The quality of fusion between the different materials was meticulously analyzed through cross-sectional observation and further substantiated by Scanning Electron Microscopy (SEM) with Energy Dispersive X-ray Spectroscopy (EDX) analysis to study the migration of various elements within the printed sample. Additionally, we report the successful hardening of the demonstrator components through aging, achieving a hardness of 50 HRC. This development not only marks a significant advancement in additive manufacturing technology but also broadens the spectrum of applications for multi-material 3D printing, including different polymeric materials for soft robotics.

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Keywords

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