Mastering binder jet 3D printing of 316L stainless steel: A descriptive model approach to particle size and deposition thickness

To fill the gap in a rational strategy for materials selection and process optimization, the effect of 3D binder jetting on the packing density and pore structure of AISI 316L SS powders with a wide range of particle sizes (d = 5-60 µm) and deposition thicknesses (1≤H/d≤10) were investigated. We introduce a new dimensionless parameter, φ=1-(d/H)21+(d/H), and demonstrate that the packing density and binder-induced pores abruptly varies with φ in a semi-log scale and d−2, respectively. In light of the mechanistic understanding of the transient behavior, the optimum d/H value to attain dense and homogeneous parts is proposed.