Rapid Prototyping of Powder Binder Mixtures using the Multiphase Jet Solidification (MJS) process

The commercial Rapid Prototyping processes fulfill the need of functional prototypes only for a few materials. For this reason today most of the metallic prototypes are produced in a two step process. The part is designed on a 3D CAS system and built with a Rapid Prototyping system out of a wax or a castable material. In a second step the part is produced in a metallic alloy by an investment casting process. But this procedure cuts down the time reduction that can be reached by using Rapid Prototyping. In order to fulfill the requirements for the direct production of metallic and ceramic prototypes for functional application and testing, the development of new processes and materials are key research areas. Some approaches are on the basis of powder metallurgical techniques. A new process named Multiphase Jet Solidification (MJS) has been developed, able to produce metallic or ceramic parts out of powder-binder mixtures in a freeforming manner.