Defects in sinter-based AM
Defects in sinter-based AM
Common defects of Binder Jetting and Metal Extrusion
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What you will find in this section
Disregard of design guidelines
Reason
- Insufficient wall thickness
- Unsupported structures like overhangs and holes
- Orientation of the part
Mitigation
- Follow design rules of the specific process and material
- Optimize process parameters depending on geometry.
Insufficient 3D CAD data
Reason
- Resolution of stl file too low
- Defect stl file
Mitigation
- Adapt CAD program settings (increase resolution of tesselation)
- Adapt conversion settings and repair STL file
Poor powder quality
Reason
- Insufficient flowability due to particle shape and size, humidity and virgin powder
- Contamination due to poor recycling process
Mitigation
- Improve storage of powder
- Follow giving handling and recycling guidelines
- Check regularly
Deformation
Reason
- Process induced internal stresses
- Insufficient support structures
- Poor orientation
Mitigation
- Improve support structures, orientation, process parameters and scanning strategy
Incorrect process parameters
Reason
- Energy input too low / high
- Poor scanning strategy
Mitigation
- Development of robust material and part specific process parameters
Insufficient heat treatment
Reason
- Incorrect heat treatment parameters (e.g. temperature, duration, inert gas)
Mitigation
- Improve heat treatment in accordance to material and part design