• Drying time of specimens increased with increased volume content. Figure 4,

represents the comparison of drying times of specimen with varying volume contents.

Rapid Prototyping also referred to as rapid manufacturing, additive manufacturing, 3D

printing and solid-freeform (SFF) technology was first introduced by Charles Hull in the

early 1980’s. [1]. It is expected that 3D printer market including hardware, materials and

services increases from “4.1 billion in 2015 to 16.2 billion by 2020” [2]. 3D Powder

printing also called as Binder Jetting process is a type of SFF, which is very attractive

since it rapidly produces 3D geometries. Due to the increased demand in 3D printing

systems, there is an increased demand in materials. Material limitation is a major

problem concerning the 3D printing world. Innovative materials are continuously being

developed in 3D printing process, including metals, ceramics and polymers with suitable

properties viable for 3D printing [3]. Particularly, for 3D powder printing, formulation

of powder and binder system needs many considerations which include both process

details and post treatment of the final printed specimens [3].

INTRODUCTION

BINDER JETTING PROCESS ALGORITHM

APPLICATIONS

OBJECTIVES

INITIAL EXPERIMENT METHODOLOGY

• Preparation of specimens with different algae powder (EAP, NEAP) and binder (WAO,

Zb56) combinations.

i. With constant mass of powder equal to one gram, two different types of powders are

mixed with two different types of binders making a total 4 powder/binder composites.

• Powder to binder ratios was varied to identify the best composite ideal for 3D printing.

i. Initial specimens were prepared with constant mass of powder equal to one gram and

varying volume of binder between 0.60 ml – 0.85 ml.

PRELIMINARY RESULTS AND DISCUSSION

• By retaining shape of mold when mixed with suitable binder, a powder demonstrates that it

has the properties capable to 3 D print.

NEAP-WAO

•WAO volume: 0. 5ml.

•Status of Printing: No.

•Details of specimen: Non homogenous mixture, could not retain shape of mold, long drying times.

NEAP-Zb56

•Zb56 volume: 0.5 ml.

•Status of Printing: No.

•Details of specimen: Binder could not hold particles together.

EAP-WAO

•WAO volume: 0.75 ml.

•Status of Printing: Yes.

•Details of specimen: Homogenous mixture, Specific drying time, able to retain shape of mold.

EAP-Zb56

•Zb56 volume: 2 ml.

•Status of Printing: No.

•Details of specimen: Binder could not hold the particles of powder.

• Alkyds are formed from alkyl and acids due to a polymerization reaction between alcohol

(glycerol) and dicarboxylic acid. Below is the reaction of polymerization [4].

• The oil portion of the polyester reacts with the chemical composition of algae in the

presence of oxygen forming cross-linking reactions [4].

WAO volume: 0.6ml

• Insufficient volume.

WAO volume: 0.65-0.67ml

• Specimens look alike and poor surface finish.

WAO volume: 0.70-0.77ml.

• Specimens look alike.

• Good surface finish.

WAO volume: 0.8-0.83ml.

• Specimens look alike.

• Poor surface finish.

WAO volume: 0.85ml.

• Specimen remain wet till now.

43 4351

6267

72

110

120

0

20

40

60

80

100

120

140

0.65 0.67 0.7 0.73 0.75 0.77 0.8 0.83

Dry

ing

tim

e (h

ou

rs)

Volume of binder per gram powder(ml)

comparision of drying times

Specimen is taken out of powder bed

Post processing of the

SpecimenFINISH

START

Automatic

deposition of

powder layer

Print head deposits

binder on to the

powder layer

Add another

layer

YES

NO

INITIAL EXPERIMENT MATERIALS

• Two types of algae powder are used in doing initial experiments Edible algae powder

(EAP) and Non edible algae powder (NEAP).

• Alkyds are used as binders for research purpose because they have the adhesive ability to

bind any powder[3]. Walnut alkyd oil (WAO) and water based Z-corporation Zb56 are used

as binders.

Figure 2: Picture of Edible algae powder Figure 3: Picture of Non Edible Algae Powder

• Identification of powder and binder combinations that are suitable for powder

printing.

• Identification of material system features required for powder printing.

• Exploring process parameters for achieving optimum powder-printed prototypes.

• Development of appropriate post processing techniques to improve the structural

properties and mechanical properties of specimens.

Measurement of powder and

Binder

Mixing powder and binder. Place them in a mold

Allow the specimens to dry

at room temperature

REFERENCES

• Combination of edible algae powder(EAP) and walnut alkyd oil(WAO) are found

viable for 3D Powder printing.

• Binder (WAO) volume of 0.7ml per gram of powder (EAP) is found to be the best

observation in terms of drying time (51 hours) and surface roughness.

• Cylindrical specimens made of EAP-WAO combination with characteristic volumes

of WAO are subjected to thermal treatment.

• Structural and mechanical tests are conducted on the specimens.

[1] B. C. Gross, J. L. Erkal, S. Y. Lockwood, C. Chen and S. Dana M, "Evaluation of 3D Printing and Its Potential Impact on Biotechnology and the Chemical Sciences.," Analytical Chemistry , pp. 3240-253, 2014.[2] P. Kunert, http://www.theregister.co.uk/2016/04/05/3d_printer_sales/. Date of access. 04/02/2016.[3] B. Utela, D. Storti, R. Anderson and M. Ganter, "A review of process development steps for new material systems in three dimensional printing ( 3DP )," Journal of Manufacturing Processes, pp. 96-104, 2008.[4] The Editors of Encyclopedia Britannica, "Alkyd resin," http://www.britannica.com/science/alkyd-resin, 2016. Date of access. 04/02/2016

CONCLUSION AND FUTURE WORK

Figure 4. Comparison of drying times with increase in binder volume per gram.

NOVEL MATERIAL SYSTEMS FOR 3D POWDER PRINTINGNanomaterials and Energetics System Lab (NESL)

Department of Mechanical EngineeringRuss College of Engineering and Technology

Presenter: Pragnya Kunchala, BSMEAdvisors: Keerti Kappagantula, PhD (Mechanical Engineering)

Dušan N. Šormaz, PhD (Industrial and Systems Engineering)Jesus Pagan, MS (Engineering Technology and Management)

Figure 1: Applications of 3D printing process. (Source: Wohlers Report)

3D PRINTING

CONSUMER PRODUCTS/

ELECTRONICS

MOTOR VEHICLES

MEDICAL/ DENTAL

INDUSTRIAL/ BUSINESS

MACHINES

AEROSPACEACADEMICINSTITUTIONS

GOVERNMENT/MILITARY

ARCHITECT-URAL

OTHER