Binder jetting of well-controlled powder agglomerates for breakage studies

Based on the similarity between the solidification process of the Additive Manufacturing (AM) binder jetting technique and wet granulation mechanisms, binder jetting is used to print powder granules with controlled geometry and strength. Powder granules with different strengths were achieved by changing the printing parameters, including the layer thickness and saturation level. The printed powder granules were then characterised for their structural properties such as their porosity and printing accuracy. Different parameter settings were found to have a significant influence on surface roughness. The strength of powder granules was improved by increasing the print saturation level, without compromising the printed geometry. A breakage study was carried out by compression tests of granules printed with different shapes and strengths. The relationship between print setting, structure and strength was established and discussed. This study demonstrates that AM powder granules with designed shapes and well-controlled strengths may act as ideal calibration particles for a range of industrial applications.