Validation of Process Parameters for Binder Jetting of Gears (17-4PH)

Binder Jetting (BJT) of gears is a multi-stage additive manufacturing (AM) process that generates part geometry by depositing a liquid binder in a powder bed layerwise. The BJT process produces green compacts of gears that are sintered by secondary heat treatment processes. The impact of various process parameters on the reproducible manufacturing of gears has not been systematically investigated. The selection of process parameters, such as printing speed and binder volume, is often an iterative process based on the knowledge of both the user and machine manufacturer. Previous studies have primarily focused on binder application phenomena and do not provide validation for the mentioned process parameters for gear manufacturing. This report presents a systematic method for validating the printing speed and binder quantity in terms of reliability, productivity, and economy for manufacturing BJT gears. The knowledge gained allows for the determination of optimal process parameters based on experimental data.