ExOne Achieves Scientific Breakthrough: Automotive Industry-First Binder Jet Aluminum 3D Printing and High-Density Sintering
- New patent-pending process developed by
ExOne and Ford Motor Co. for binder jetting 6061 aluminum, one of the most commonly used aluminum alloys in the world, delivers final parts with 99% density and material properties comparable to traditional manufacturing - Sintering precision parts in aluminum can unlock new benefits in manufacturing, such as new lightweight part designs that improve system design and performance
- This rapid and reliable process for future production of aluminum parts is much faster than other 3D printing methods and capable of scaling to the volumes needed for automotive use
Ford andExOne are actively working on designs to use the new material and process
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This aluminum 6061 engine block model demonstrates the high resolution and geometric control that can be produced in a new patent-pending binder jet 3D printing and sintering process developed by
Delivering a commercially viable achievement in this area has evaded researchers for more than a decade. Collaborative and individual patents are expected to be filed by
Some aluminum alloys can be 3D printed today using lasers, but the process is much slower than the one developed by
“This is a breakthrough in making 3D printed and sintered parts for the auto industry,” said
“Developing a fast, affordable, and easy way to 3D print aluminum with traditional material properties is a critical step toward light-weighting more products and delivering a more sustainable future,” said
The new innovation came about through the process of binder jetting, widely regarded as the fastest method of metal 3D printing for high-volume output. It uses a digital file to quickly inkjet a binder into a bed of powder particles such as metal, sand, or ceramic to create a solid part, one thin layer at a time. When printing metals, the final bound metal part must be sintered in a furnace to fuse the particles together into a solid object. The heating process reinforces the strength and integrity of the metal, and while the process for sintering stainless steel is well understood, achieving high densities greater than 99 percent is an industry breakthrough for aluminum.
The Ford-ExOne joint development project was first initiated in 2019.
The relationship between
For more information about today’s announcement, such as high-resolution photos, video and more information about the technology, visit www.exone.com/aluminum.
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