As metal Binder Jetting (BJT) transitions from a technology for the future to a technology for now – and one that is increasingly being installed at Metal Injection Moulding producers around the world – one of the basics of the process that we can no longer avoid getting to grips with is saturation. In this article, longtime metal Binder Jetting expert Dan Brunermer, from technology consultancy B-jetting LLC, explains saturation and how to measure it, considers voxels and DPI, and finally presents control options and how choices in controls affect saturation.
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No matter which market report you choose to believe, all recent analysis of the ceramic AM market points to major growth. But this is still an emerging technology, and in terms of its commercial development, ceramic AM is said to be five years behind metal AM. Now, as global manufacturers of high-performance ceramics enter the market, an even faster acceleration in technology adoption is promised. Here, Claus Falkner, of CeramTec, a producer of technical ceramics by processes that include Ceramic Injection Moulding, explores the benefits of ceramic Binder Jetting and considers the process as a compelling solution for complex parts.
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There can be few Metal Injection Moulding companies which are not keeping one eye on metal Binder Jetting (BJT). This rapidly progressing Additive Manufacturing process offers the promise of tool-free, high-volume production that can leverage much of an existing MIM producer’s expertise and equipment. Indo-MIM Inc., one of the world’s largest MIM producers, with operations in India and the US, started its exploration of Binder Jetting in 2019. Here, the company’s Jag Holla shares his insight into what the company has learnt so far, and where he sees the dividing line between MIM and BJT.
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The combination of generative and algorithmic design with Additive Manufacturing is opening up a new world of opportunity for ceramics. Whilst Ceramic Injection Moulding has, until now, been the manufacturing process that offered the greatest level of design freedom for industrial production, ceramic AM now brings a level of freedom to produce complex structures that go far beyond what can be moulded. Prof Alberto Ortona, from the Hybrid Materials Laboratory at University of Applied Sciences and Arts of Southern Switzerland (SUPSI), explores ceramic Binder Jetting, the opportunities that it presents, and its current limitations.
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In recent years there has been a surge in interest in sinter-based metal Additive Manufacturing, with many of these technologies adapting the materials used in Metal Injection Moulding. Whilst Binder Jetting (BJT) and Material Extrusion (MEX) processes lead the field in terms of market penetration, sometimes something radically different comes along. This is certainly the case with Germany’s Headmade Materials, whose Cold Metal Fusion (CMF) AM process takes a completely new approach. Dr Georg Schlieper visited the company and reports for PIM International on the company and its technology.
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SSI Sintered Specialties, LLC can trace its roots back to the earliest days of Powder Metallurgy in the US. True to its name, that company has over the decades found success through specialisation, in particular stainless steel PM products. This is a theme that continues today, with the company now expanding its horizons through the development of large Metal Injection Molding parts using innovative feedstock technology, and the adoption of metal Binder Jetting. Bernard North visited the company on behalf of PIM International and reports on its plans to remain at the forefront of metal powder based parts production.
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Binder Jetting – at once the new kid on the block yet one of the industry’s earliest processes – holds the promise of taking metal Additive Manufacturing into the territory of true high-volume production. Yet progress towards this goal appears to be struggling, with machine sales lower than many hoped and two new ‘big players’ appearing to be holding back on full commercialisation. In this report, Joseph Kowen considers the development of this industry to date, the obstacles facing its growth, and, of course, the recent announcement of two of Binder Jetting’s biggest rivals coming together in the most unexpected acquisition.
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In this article, Dr Samuel von Karsa-Wilberforce, Emery Oleochemicals, Germany, and co-authors report on the tensile strength of sintered 316L specimens produced via Fused Filament Fabrication (FFF), a Material Extrusion (MEX)-based Additive Manufacturing process. The parameters studied include printing nozzle temperature, flow percent or extrusion multiplier and nozzle diameter of print head. The 316L feedstock filaments are based on Emery Oleochemicals’ evolutionary binder system, which has been used in MIM for more than thirty years. The partner in the study for debinding, sintering and mechanical testing is CMG Technologies Ltd, UK.
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The synergies between Metal Injection Molding and metal Binder Jetting are well known. Leveraging these synergies with the intention of accelerating binder jet application development is FreeFORM Technologies, whose team includes several experienced former MIM industry professionals. Here, FreeFORM’s Nate Higgins, Chris Aiello, Eric Wonderling and Meghan Kephart explore what has held Binder Jetting back until now, and how they intend to overcome these barriers.
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MIMplus Technologies has a proven track record in MIM materials, process and application development. Now, the company is further increasing its market reach and production capability through research-driven material and process developments. As Dr Georg Schlieper explains, the first of the company’s two main areas of current innovation is the production of NdFeB hard magnets, using recycled materials, by MIM. The second is in sinter-based Additive Manufacturing, where MIMplus is working closely with Germany’s Headmade Materials and Israel’s Tritone Technologies on the commercial development of their very distinct production processes.
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