Binder jet additive manufacturing: a review of modelling approaches and experimental observations on green part printing

Binder jet additive manufacturing is a non-beam-based technique that fabricates near-net-shaped three-dimensional parts by selectively depositing a binder onto a powder bed. The binder jet printed and cured component known as green part influences subsequent post-processing to achieve the required density and mechanical properties. Despite its potential for high-throughput, low-cost production, industrial adoption remains slow due to limited understanding of binder-powder interactions. This review presents a modelling-driven understanding of green part fabrication in binder jet additive manufacturing, with a focus on computational models that describe the transition from individual binder droplet dynamics to their combined interactions with the powder bed. Models capturing the effect of binder droplet parameters were examined alongside those simulating the influence of powder feedstock characteristics. Additionally, the review explores data-driven modelling approaches aimed at optimising green part fabrication. Experimental observations are incorporated to enhance understanding and establish clear correlations between model predictions and observed binder-powder behaviour. The review concludes with a focus on enabling better process control and scalability in binder jet printing through the synergistic integration of modelling frameworks and empirical validation. Future directions are suggested to enhance computational/predictive capabilities and support the development of reliable, application-specific green part fabrication workflows.