Binder jetting additive manufacturing: observations of compaction-induced powder bed surface defects

This paper, for the first time, reports observations of a type of powder bed surface defects (i.e., surface ridges) induced by forward-rotating roller compaction. Three compaction thicknesses, 0, 30, and 180 mm, were tested at a layer thickness of 120 mm. Surface ridges occurred on the powder bed surface when compaction thickness was 180 mm, but not when compaction thickness was 0 or 30 mm. The formation of surface ridges was a cumulative process where the number and height of surface ridges first increased and then reached a plateau as the number of spread and compacted layers increased. (C) 2021 Society of Manufacturing Engineers (SME). Published by Elsevier Ltd. All rights reserved.

Automated summary

This study reports for the first time surface defects induced by forward-rotating roller compaction, showing that the formation of surface ridges is a cumulative process that reaches a plateau as the number of layers increase.