ExOne introduces the X1 160PRO, a metal binder jetting 3D printer that can printer objects of up to 800 by 500 by 400mm. The 3D printer thus offers a build volume as much as 2.5 times larger than that of competitors, reports ExOne.
Metal binder jetting is a form of 3D printing that uses powdered material, which is deposited in one layer on the print bed. By printing a liquid binder onto the powder bed with great accuracy, this powder is cured, allowing for the production of 3D objects layer by layer. The technique is mainly used for printing objects in metal, sand or ceramics.
Large build volume
With the X1 160PRO, ExOne says it is marketing a 3D printer with an exceptionally large build volume. The printer offers a build volume of 800 by 500 by 400mm, equivalent to a volume of 160 litres. With this, ExOne is targeting the production of components for the automotive, aerospace and defence sectors, among others.
The X1 160PRO is capable of printing six different metals, including the stainless steel alloys 316L, 304L and 17-4PH. It is also possible to print a number of ceramic shapes. Printing can be done at speeds of up to 10,000 cm3 per hour. The printing speed achieved in practice depends on the material being printed; the speed is automatically optimised for the chosen material. With the new 3D printer, ExOne aims to enable the manufacture of high-quality parts at production speeds.
Layer by layer
In metal binder jetting, a new layer of powdered material is placed on the print bed before printing each layer of an object. This layer is cured at the desired locations, after which the process is repeated to create the next layer. To make this printing process possible, the powder material must be evenly distributed on the print bed.
While this may sound simple, in practice it is very challenging. For instance, the cohesion of individual powder grains can lead to a phenomenon called 'caking', the tendency of powder material to form clumps. In addition, the liquid binder deposited on the powder material can displace individual powder grains, creating wrinkles, for instance.
Distributing powder evenly
One of the major challenges in metal binder jetting is therefore the even distribution of this powdered material. Not only must this material be evenly distributed on the print bed, it must also be uniformly compressed. This is necessary to produce reproducible objects with consistent density; deviations in the powder bed can impact the quality of the final object.
To do this, the X1 160PRO uses the Triple Advanced Compaction Technology (ACT) system, developed in-house by ExOne. This system deploys a hopper to deposit the powdered material evenly on the print bed, a roller to spread the material as uniformly as possible and a second roller to press the material evenly. More information on how this system works can be found on the ExOne website.
The X1 160PRO is expected to ship to customers from the end of 2020.
Author: Wouter Hoeffnagel
Source: ExOne
