Dense Complex Copper Parts Obtained By Binder Jetting And Spark Plasma Sintering

Binder Jetting is capable of cost-effectively producing complex metal and ceramic components without the need for support structures. However, printed parts typically contain porosity due to the use of coarse powders and a loosely packed powder bed. For some materials, it is difficult to achieve full density without infiltration of a secondary lower melting point material. This work presents the post-densification of binder jetting parts by a pressure assisted sintering process, Spark Plasma Sintering. Sacrificial powder was used in other to maintain the complex geometry. Copper pieces were successfully densified using different starting conditions. However, densification of the pieces was not isotropic, and thus some design considerations are explained in order to obtain the right geometry. Additionally, considerations about the possible scalability and industrial application of this approach are also presented.