Friction-induced distortion in binder jetted 316 L stainless steel: Experimental analysis, simulation, and compensation strategy

• This work identifies key factors influencing density in 3D-printed binder-jetted parts. ○ Printing parameters: binder saturation strongly affected green density, which ranged from 52% to 58% of relative density. ○ Printing level (Z): green density slightly decreased with increasing distance from the build platform, varying by 0.5–2% depending on binder saturation. ○ Printing direction (X–Y): green density was slightly higher along the powder spreading direction than the binder injection direction, by 0.53–0.65%. • After sintering, samples achieved near-full density (98–99%), confirming the effectiveness of a hydrogen-rich atmosphere. Dimensional change was strongly influenced by the initial green density. • After sintering, samples exhibited significant shape distortion, attributed to: ○ Friction-induced deformation: simulations confirmed the negative effect of friction between the sample surface and the support. ○ Density-induced deformation: simulations confirmed the role of density variation along the printing direction in generating distortion. • A compensation strategy was proposed to limit friction-induced deformation. Placing samples on a BJ support prevented distortion, keeping the deviation from the target geometry within 1.5% of linear dimensions. This study investigates the origin of distortion during sintering of 316L stainless steel components produced by binder jetting, focusing on friction between the sample and the support surface and on density inhomogeneity in the green state. A design of experiments (DoE) approach evaluates the influence of key printing parameters on the sintering behavior of two geometries with different through-hole sizes. Dimensional measurements, and density profiling, are performed in both green and sintered states. Sintering simulations use the Skorokhod-Olevsky viscous sintering (SOVS) model and include experimentally measured density gradients and frictional effects. Results show that green density varies significantly (52% to 58%) depending on printing parameters, especially binder saturation, and exhibits directional dependence. These variations lead to measurable distortions during sintering. Simulations that include both friction and density gradients match experimental deformations with deviations below 4%. A compensation strategy that places parts on co-sintered 316L support plates with interposed refractory particles reduces distortion to less than 1.5%. This work demonstrates the combined role of friction and density gradients in sintering distortion and presents a practical method to improve dimensional accuracy in binder jetting.