1. • Drying time of specimens increased with increased volume content. Figure 4,
represents the comparison of drying times of specimen with varying volume contents.
Rapid Prototyping also referred to as rapid manufacturing, additive manufacturing, 3D
printing and solid-freeform (SFF) technology was first introduced by Charles Hull in the
early 1980’s. [1]. It is expected that 3D printer market including hardware, materials and
services increases from “4.1 billion in 2015 to 16.2 billion by 2020” [2]. 3D Powder
printing also called as Binder Jetting process is a type of SFF, which is very attractive
since it rapidly produces 3D geometries. Due to the increased demand in 3D printing
systems, there is an increased demand in materials. Material limitation is a major
problem concerning the 3D printing world. Innovative materials are continuously being
developed in 3D printing process, including metals, ceramics and polymers with suitable
properties viable for 3D printing [3]. Particularly, for 3D powder printing, formulation
of powder and binder system needs many considerations which include both process
details and post treatment of the final printed specimens [3].
INTRODUCTION
BINDER JETTING PROCESS ALGORITHM
APPLICATIONS
OBJECTIVES
INITIAL EXPERIMENT METHODOLOGY
• Preparation of specimens with different algae powder (EAP, NEAP) and binder (WAO,
Zb56) combinations.
i. With constant mass of powder equal to one gram, two different types of powders are
mixed with two different types of binders making a total 4 powder/binder composites.
• Powder to binder ratios was varied to identify the best composite ideal for 3D printing.
i. Initial specimens were prepared with constant mass of powder equal to one gram and
varying volume of binder between 0.60 ml – 0.85 ml.
PRELIMINARY RESULTS AND DISCUSSION
• By retaining shape of mold when mixed with suitable binder, a powder demonstrates that it
has the properties capable to 3 D print.
NEAP-WAO
•WAO volume: 0. 5ml.
•Status of Printing: No.
•Details of specimen: Non homogenous mixture, could not retain shape of mold, long drying times.
NEAP-Zb56
•Zb56 volume: 0.5 ml.
•Status of Printing: No.
•Details of specimen: Binder could not hold particles together.
EAP-WAO
•WAO volume: 0.75 ml.
•Status of Printing: Yes.
•Details of specimen: Homogenous mixture, Specific drying time, able to retain shape of mold.
EAP-Zb56
•Zb56 volume: 2 ml.
•Status of Printing: No.
•Details of specimen: Binder could not hold the particles of powder.
• Alkyds are formed from alkyl and acids due to a polymerization reaction between alcohol
(glycerol) and dicarboxylic acid. Below is the reaction of polymerization [4].
• The oil portion of the polyester reacts with the chemical composition of algae in the
presence of oxygen forming cross-linking reactions [4].
WAO volume: 0.6ml
• Insufficient volume.
WAO volume: 0.65-0.67ml
• Specimens look alike and poor surface finish.
WAO volume: 0.70-0.77ml.
• Specimens look alike.
• Good surface finish.
WAO volume: 0.8-0.83ml.
• Specimens look alike.
• Poor surface finish.
WAO volume: 0.85ml.
• Specimen remain wet till now.
43 43
51
62
67
72
110
120
0
20
40
60
80
100
120
140
0.65 0.67 0.7 0.73 0.75 0.77 0.8 0.83
Dryingtime(hours)
Volume of binder per gram powder(ml)
comparision of drying times
Specimen is
taken out of
powder bed
Post processing
of the
Specimen
FINISH
START
Automatic
deposition of
powder layer
Print head deposits
binder on to the
powder layer
Add another
layer
YES
NO
INITIAL EXPERIMENT MATERIALS
• Two types of algae powder are used in doing initial experiments Edible algae powder
(EAP) and Non edible algae powder (NEAP).
• Alkyds are used as binders for research purpose because they have the adhesive ability to
bind any powder[3]. Walnut alkyd oil (WAO) and water based Z-corporation Zb56 are used
as binders.
Figure 2: Picture of Edible algae powder Figure 3: Picture of Non Edible Algae Powder
• Identification of powder and binder combinations that are suitable for powder
printing.
• Identification of material system features required for powder printing.
• Exploring process parameters for achieving optimum powder-printed prototypes.
• Development of appropriate post processing techniques to improve the structural
properties and mechanical properties of specimens.
Measurement of
powder and
Binder
Mixing powder
and binder. Place
them in a mold
Allow the
specimens to dry
at room
temperature
REFERENCES
• Combination of edible algae powder(EAP) and walnut alkyd oil(WAO) are found
viable for 3D Powder printing.
• Binder (WAO) volume of 0.7ml per gram of powder (EAP) is found to be the best
observation in terms of drying time (51 hours) and surface roughness.
• Cylindrical specimens made of EAP-WAO combination with characteristic volumes
of WAO are subjected to thermal treatment.
• Structural and mechanical tests are conducted on the specimens.
[1] B. C. Gross, J. L. Erkal, S. Y. Lockwood, C. Chen and S. Dana M, "Evaluation of 3D
Printing and Its Potential Impact on Biotechnology and the Chemical Sciences.,"
Analytical Chemistry , pp. 3240-253, 2014.
[2] P. Kunert, http://www.theregister.co.uk/2016/04/05/3d_printer_sales/. Date of
access. 04/02/2016.
[3] B. Utela, D. Storti, R. Anderson and M. Ganter, "A review of process development
steps for new material systems in three dimensional printing ( 3DP )," Journal of
Manufacturing Processes, pp. 96-104, 2008.
[4] The Editors of Encyclopedia Britannica, "Alkyd resin,"
http://www.britannica.com/science/alkyd-resin, 2016. Date of access. 04/02/2016
CONCLUSION AND FUTURE WORK
Figure 4. Comparison of drying times with increase in binder volume per gram.
NOVEL MATERIAL SYSTEMS FOR 3D POWDER PRINTING
Nanomaterials and Energetics System Lab (NESL)
Department of Mechanical Engineering
Russ College of Engineering and Technology
Presenter: Pragnya Kunchala, BSME
Advisors: Keerti Kappagantula, PhD (Mechanical Engineering)
Dušan N. Šormaz, PhD (Industrial and Systems Engineering)
Jesus Pagan, MS (Engineering Technology and Management)
Figure 1: Applications of 3D printing process. (Source: Wohlers Report)
3D
PRINTING
CONSUMER
PRODUCTS/
ELECTRONICS
MOTOR
VEHICLES
MEDICAL/
DENTAL
INDUSTRIAL/
BUSINESS
MACHINES
AEROSPACEACADEMIC
INSTITUTIONS
GOVERNMENT/
MILITARY
ARCHITECT-
URAL
OTHER