Binder jetting at scale: Series production with sand and pathways to industrialization of slurry-based 3D printing

• Slurry-based binder jetting enables processing of fine powders to high part density • Modular printer and inline process monitoring allow for closed-loop drying control • Layer drying time is identified as the key driver of production cost • Design rules link part, material and additive manufacturing process requirements • Use cases in medicine, aerospace, and casting show the industrial potential Binder jetting has progressed from rapid prototyping of sand molds and cores to a robust, series-production technology in foundries, enabled by advances in machine reliability, build speed, and material–process co-optimization. High-performance castings increasingly rely on complex 3D-printed cores beyond conventional tooling. In parallel, ceramic binder jetting is earlier in its industrialization, with key barriers - low green density, limited strength, high surface roughness, and sintering shrinkage - now being tackled by slurry-based binder jetting of fine powders. This article synthesizes the evolution of slurry-based binder jetting, highlights recent process innovations with demonstrated industrial relevance, critically evaluates their transferability to industrial practice, and outlines a prospective roadmap for future use cases. The analysis indicates that slurry-based binder jetting is not yet ready for series production but is technically poised for broad adoption in cost-effective manufacture of medium- to large-sized ceramic and metal parts across medical, aerospace, and electronics applications.