Effects of Roller Traverse Speed and Roller Rotational Speed on Powder Bed Density and Green Part Density in Binder Jetting Additive Manufacturing

Abstract

This study investigates the effects of two process parameters (roller traverse speed and roller rotational speed) on powder bed density and green part density in binder jetting additive manufacturing using silicon carbide powder at higher powder dispense amount (longer dispense delay and slower recoat speed). Roller traverse speed and roller rotational speed are used to spread the powder across the powder bed and affect powder packing. Experiments were conducted at three levels of roller traverse speed (5, 10, and 15 mm/ s) and three levels of roller rotational speed (100, 200, and 300 rpm). As roller traverse speed increased from 5 to 15 mm/s, powder bed density decreased from 2.12 to 1.70 g/cm³, while the corresponding average green part density decreased from 1.72 to 1.58 g/cm³. Increasing roller rotational speed from 100 to 300 rpm reduced powder bed density from 2.13 to 1.69 g/cm³ and green part density from 1.72 to 1.59 g/cm³. The one-way ANOVA results reveal that both roller traverse speed and roller rotational speed have statistically significant effects on powder bed density and green part density. These findings provide useful insights into optimizing binder jetting additive manufacturing process parameters to achieve desired green part density without employing powder bed compaction.