How do you choose between powder bed fusion and binder jetting for metal 3D printing?

1 Powder bed fusion

Powder bed fusion (PBF) is a metal 3D printing process that uses a heat source, such as a laser or an electron beam, to selectively melt and fuse metal powder particles together. The heat source scans the cross-section of the part layer by layer, creating a solid metal object. PBF can produce high-quality, high-strength, and high-density parts with fine details and complex geometries. However, PBF also has some drawbacks, such as high cost, long processing time, high energy consumption, and limited material options.

2 Binder jetting

Binder jetting (BJ) is another metal 3D printing process that uses a print head to deposit a liquid binder onto a bed of metal powder, forming the shape of the part layer by layer. The binder acts as a glue that holds the powder particles together, creating a green part that is then sintered in a furnace to remove the binder and densify the metal. BJ can produce parts faster, cheaper, and with more material diversity than PBF. However, BJ also has some limitations, such as lower mechanical properties, lower dimensional accuracy, and higher post-processing requirements.

3 Part size and complexity

One of the factors that can influence your choice between PBF and BJ is the size and complexity of your part. PBF can create smaller and more intricate parts than BJ, as it can melt and fuse powder particles with high precision and resolution. However, PBF also has a limited build volume and requires support structures to prevent deformation and warping. BJ can create larger and simpler parts than PBF, as it can deposit binder onto a wider area and does not need support structures. However, BJ also has a lower resolution and may introduce defects and porosity during sintering.

4 Part function and performance

Another factor that can affect your decision between PBF and BJ is the function and performance of your part. PBF can create parts that have higher strength, hardness, and durability than BJ, as it can achieve full density and metallurgical bonding of the metal. However, PBF also can create residual stresses and distortions that may compromise the part's integrity and reliability. BJ can create parts that have lower weight, higher flexibility, and higher design freedom than PBF, as it can incorporate different materials and gradients into the part. However, BJ also can create parts that have lower density, lower stiffness, and lower resistance to fatigue and corrosion than PBF.

5 Part cost and time

A final factor that can influence your choice between PBF and BJ is the cost and time of your part. PBF can create parts that have higher quality and consistency than BJ, as it can control the temperature and atmosphere of the process and avoid contamination and oxidation of the metal. However, PBF also can create parts that have higher cost and longer time than BJ, as it requires expensive equipment, materials, and maintenance, as well as slow scanning speeds and cooling cycles. BJ can create parts that have lower cost and shorter time than PBF, as it requires cheaper equipment, materials, and operation, as well as faster printing speeds and no cooling cycles. However, BJ also can create parts that have lower quality and consistency than PBF, as it requires additional steps of sintering, infiltration, and finishing to achieve the desired properties and appearance of the part.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?