3D Printer Metal Binder Jetting (BJ)

Binder jetting (BJ) in additive manufacturing

How a metal 3D printer with binder jetting works

A binder jetting 3D printer is an additive manufacturing machine that builds metal parts layer by layer from powdered metal (powder bonding). Unlike other 3D printing processes such as selective laser melting (SLM) or electron beam melting (EBM), the binder jetting process does not use a laser or electron beam to melt the material. Instead, a liquid binder is applied to a thin layer of metal powder to bond the particles locally. A new layer of powder is then applied and the process is repeated until the desired component is completely built up.

After printing, the component is in what is known as the "green state" – it is still porous and does not have sufficient strength. It therefore undergoes a further debinding and sintering process. First, the liquid binder is removed (debinding) and the component is then sintered at a high temperature. During this process, the metal particles fuse to form a dense, stable metal component with almost fully metallic properties.

The binder jetting process is particularly suitable for the series production of complex metal components, as it enables high construction speeds and comparatively cost-effective production without complex support structures. Typical metals that can be processed include stainless steel, tool steel, copper, Inconel, and titanium. The high degree of design freedom and the ability to produce multiple components simultaneously make metal 3D printers with binder jetting an attractive technology for industry, research, and development.

Other types of metal 3D printers

At maschinenauswahl.de, you will find an overview of all 3D additive manufacturing metal technologies. Other processes include:

Components of a BJ printer

The powder bed forms the basis on which the layers of metal powder are applied. A precision roller or squeegee ensures that the powder is distributed evenly. The print head is equipped with nozzles that apply the liquid binder to the powder bed in a targeted manner. A build platform lowers precisely after each layer to make room for the next layer of powder. The machine also includes a cleaning station, a powder feeder, and a control unit. Separate debinding and sintering furnaces are required for post-processing.

Binder jetting in industrial manufacturing

Metal 3D printers with binder jetting are primarily used in industries that rely on complex metal components in medium to large quantities. The process is particularly widespread in the automotive industry, aerospace, medical technology, toolmaking, mechanical engineering, consumer goods industry, as well as among electronics manufacturers and in energy technology. The high degree of design freedom allows for the economical production of functionally integrated, weight-optimized, or difficult-to-machine components.

Examples of workpieces produced using metal 3D printing with binder jetting:

Turbocharger housing
Heat exchangers
Tool inserts
Implants
Gear components
Mounts
Spray nozzles
Electrical enclosures
Copper contacts
Decorative design objects

Prototypes with near-series properties can also be produced quickly and cost-effectively. The technology is also ideal for manufacturing customized or functionally optimized components that would be difficult or impossible to produce using conventional methods.

Materials and metals for binder jetting

Binder jetting is an extremely flexible process that is compatible with a wide range of metallic materials. Stainless steel, such as 316L or 17-4PH, is particularly frequently used due to its good availability, mechanical properties, and corrosion resistance. Tool steels such as M2 or H13 are also common materials for applications in mold making and industry.

Nickel alloys (e.g., Inconel 625 and 718) are used for high-performance applications, particularly in aviation and energy technology. Titanium alloys such as Ti-6Al-4V can also be processed, although special sintering conditions are required.

Other metals that can be processed include copper (due to its high thermal and electrical conductivity), bronze, cobalt-chromium (e.g., for dental or medical technology), and iron and carbon steels. The selection of the appropriate metal powder depends heavily on the desired component properties and the intended use. Optimal powder quality with uniform particle size distribution is important for precise printing results.

Binder jetting aluminum

Aluminum poses special challenges for binder jetting: it oxidizes easily, which makes sintering difficult. It also has high thermal conductivity, which leads to uneven heating. Special alloys, optimized sintering profiles, and protective atmospheres are necessary to achieve dense, dimensionally stable components with good mechanical properties.

Binder Jetting Binders

Organic polymer-based binders, such as thermoplastic or solvent-based systems, are usually used in binder jetting for metal. They must be easy to print, quick-drying, and removable without leaving any residue. The choice depends on the metal powder, the printing process, and the subsequent debinding and sintering process. A few examples:

Solvent-based organic polymer resin (e.g., acrylate or epoxy resins) — often used in metal binders for subsequent removal by thermal decomposition.
Water-based polymer dispersions — in which water serves as the carrier fluid and is subsequently evaporated or expelled.
Metal-organic decomposition (MOD) as a binder precursor — a liquid metal compound that leaves behind metallic components when heated.
Two-component binders with hardener/curing agent — for example, a binder + a catalyst or hardener to increase green part strength before debinding. (Generally mentioned in the context of sinter-based AM)
Inorganic silicate-based binder (e.g., sodium silicate) — mainly used in sand-based applications in binder jetting (BJ), but principles can be applied similarly to metal BJ.

Success factors in binder jetting

First, the consistency and particle size of the metal powder is crucial – the more uniform and finer the powder, the better the compaction and subsequent surface quality. The distribution of the powder on the build platform must also be homogeneous, which is ensured by a precision squeegee or roller.

Equally important is the precise dosing and placement of the binder. The print nozzles must deliver a consistent droplet size and must not clog. Regular calibration of the print head and a clean environment prevent quality losses.

After printing, debinding and sintering are key process steps: the temperature control must be precisely matched to the material in order to avoid deformation, cracking, or insufficient density. Component design also plays a role—uniform wall thicknesses and supporting geometries promote a distortion-free sintering process.

Finally, process monitoring and quality control during and after production are crucial to ensure reproducible results at an industrial level. Modern machines offer sensor technology and software solutions for automated analysis.

Binder jetting advantages and disadvantages

A major advantage is the high printing speed, as no energy-intensive melting is necessary. In addition, the technology allows for cost-efficient production, as standard metal powders can be used and no support structures are required – saving on materials and post-processing.

Design freedom is another advantage: complex geometries, internal channels, and lightweight structures can be implemented economically. Binder jetting is also suitable for the parallel production of multiple components, which further increases productivity. The processes are fundamentally scalable and easy to automate.

On the other hand, there are some disadvantages: Since the components initially consist only of powder and binder in their "green state," complex post-processing with debinding and sintering is required. This can cause shrinkage and warping, which makes it difficult to achieve precise dimensional accuracy. Depending on the material and process control, the achievable density and strength may lag behind other processes such as SLM. In addition, binder jetting is currently still limited to certain metal alloys.

Binder jetting versus material jetting

Binder jetting and material jetting are two different additive manufacturing processes that are often confused—yet they differ significantly in terms of structure, materials, and application.

In binder jetting, a liquid binder is selectively applied to a powder bed (e.g., metal or ceramic). The binder bonds the powder particles layer by layer to form a solid green part, which is later converted into a fully-fledged metal component through debinding and sintering. This process is particularly suitable for metallic materials and industrial series production.

In material jetting, on the other hand, the actual building material itself—usually a light-curing polymer or wax—is applied directly from nozzles in droplet form. The droplets are cured layer by layer, usually using UV light. Material jetting is suitable for the production of high-precision plastic prototypes, multi-material components, or fine structures with exact coloring.

Accessories and operating materials for a binder jetting 3D printer

A metal 3D printer with binder jetting does not work with conventional cutting tools, but with specific components for the layer-by-layer construction process. These include: inkjet nozzles (for the binder), powder distributors, squeegees or rollers, heating modules, vacuum extraction, cleaning units, calibration devices, and sensors for process monitoring. Additional tools are required for post-processing: debinding furnaces, sintering furnaces, sandblasting equipment, grinding and polishing machines, and CNC machines for final dimensional machining. Ultrasonic cleaning systems and testing equipment (e.g., for density testing) are also part of the extended range of tools.

Leading manufacturers of binder jetting 3D printers

Our manufacturers directory includes companies that produce metal 3D printers for binder jetting.

The following terms are frequently searched for: 3D Systems binder jetting, Colibrium Additives binder jetting, Desktop Metal binder jetting, ExOne binder jetting, Mark3D binder jetting, Markforged binder jetting, Voxeljet binder jetting, binder jetting manufacturers, binder jetting companies

Selecting the right metal 3D printer for binder jetting

If you want to buy a binder jetting printer, there are several important features and specifications to consider.

First and foremost, the build volume is crucial—it determines the maximum size of the components that can be produced.
The resolution of the print heads and the layer thickness also influence the level of detail and surface quality.
The printing speed is relevant for productivity, especially in series production.
Compatibility with different metal powders, the availability and cost of operating materials, and the quality of the binder used are also important.
In addition, attention should be paid to automation options, energy consumption, user-friendliness of the software, and integration into existing manufacturing processes.
Reliability, maintenance requirements, and manufacturer support services also play a role.
Last but not least, post-processing equipment such as sintering and debinding furnaces are part of the overall system and must be technically compatible.

Search now on maschinenauswahl.de for the metal 3D printer for binder jetting that suits your production requirements.

Information about binder jetting

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All machines from the category Powder bonding (BJ)