MP-Erie-Co.

PREDICTIVE MODEL FOR POST-PRODUCTION INFILTRATION OF ARTIFACTS MADE

VIA BINDER-JETTING
POST-INFILTRATION IN BINDER-JETTED ARTIFACTS
Artifacts created through binder jetting manufacturing must be able to maintain the
desired strength for end use. Understanding how the combination of polymer and
ceramic powders correlates to the end strength of the specimen is crucial. Ultimate
compressive strength testing was performed on specimens using ASTM D695-15
guidelines. Print orientation was measured as an angle about the longitudinal axis of
the specimen and was incremented in 15-degree intervals. Once the specimens were
created, each group was post processed using 3 different polymers including a clear
epoxy, cyanoacrylate, and poly(methylacrylate) esther and one group was left
untreated to act as a control. These polymers were exposed to the specimen by
submerging the specimens in a bath of the desired polymer in a vacuum chamber.
After cycling the vacuum chamber to ensure degassing of the polymer and to enhance
saturation the specimens were then removed and cured using the respective methods.
Specimens in the epoxy, cyanoacrylate, and control groups were cured by air drying
while the specimens using poly(methylacrylate) esther were cured by exposure to a
temperature-controlled environment at 190 F.
COMPRESSION TESTING D695-15
Once each specimen group was completely cured, they were then exposed to
compressive loading until failure using a Baldwin machine. The results were then
recorded, the stage was cleaned of any debris, and the tests were repeated.
Adam 2
Mihalko , Robert 2
Michael , A MODEL FOR POROSITY DISTRIBUTION
Davide Piovesan1 By mapping the porosity of the saturation cone after it is filled with polymer, we can
predict the saturation gradient that occurs in the specimen. As the polymer penetrates
1Biomedical, Industrial and System Engineering
further into the specimen the polymer becomes less concentrated. This distribution
2Mechanical Engineering pattern through the specimen leaves a saturation gradient that has a minimum value of
6% that can be found at the leading edge of the saturation cone. The minimum value is
Department, Gannon University determined by the y-intercept that occurs on the average saturation cone volume
mihalko001@knights.gannon.edu graphs.
[michael011,piovesan001]@gannon.edu
ABSTRACT:
This paper proposes a predictive model for the achievable percent saturation of
artifacts fabricated with Binder-Jetting additive manufacturing. Post-Production
infiltration based on the volume of exposed polymer on the surface of the
artifact is performed so that mechanical properties can be predicted. Although
100% saturation will allow for the best mechanical properties it is not always
necessary for the end use of the artifact. Some scenarios will not need the
properties associated with complete saturation. Therefore, understanding how
to achieve a specific saturation value is necessary. Deriving a predictive model
for the expected saturation of a porous artifact has applications in the many
industries. The manufacturing of tool and die as well as end products oftentimes
needs to obtain high strength and will therefore need to have saturation values
approaching 100%. However, medical modelling of organic tissues such as
EXPERIMENTAL ESTIMATION OF POROSITY AND SATURATION
bone requires specimen with saturation that can be controlled. Therefore, the
modeling of healthy bone will require a more complete saturation while This value is the minimum achievable saturation and represents the saturation that
diseased or damaged bone can be modeled as a lower saturation value. Finally, would occur with a polymer drop size that is approaching zero. By knowing the
understanding these principles has direct applications for filtration technologies. minimum possible saturation value at the leading edge of the saturation cone and the
average porosity found in the saturation cone, we can extrapolate the saturation at any
depth in the specimen due to the linearity of the average porosity. By understanding
this relationship, it is possible to determine the maximum volume of specimen able to
be saturated with no external influences. Saturation volumes above this maximum size
will require external forcing such as positive pressure.
All Averages
0.35

Table 1: Failure mechanics observed from compressive loading 0.3

0.25

Volume Saturate [in3]

24 Hour
0.2
1 Hour
4 Hour
0.15 y = 5.7773x + 0.0729
Linear (24 Hour)
R² = 0.9584
y = 4.807x + 0.0576 Linear (1 Hour)
R² = 0.9742
0.1
y = 6.2957x + 0.0543 Linear (4 Hour)
R² = 0.9885
0.05

0
0.0000 0.0050 0.0100 0.0150 0.0200 0.0250 0.0300 0.0350 0.0400
SATURATION Volume Dripped [in3]

These specimens were then exposed to an increasing volume of 0.5 mL-

6.0 mL in 0.5 mL increments of color dyed poly(methylacrylate) esther and
the polymer was naturally wicked into the porous matrix.
Poly(methylacrylate) esther was chosen because of its low viscosity and
controllable curing method.
CONCLUSIONS
Saturating a porous matrix with a polymer is reliant on many properties, including the
reaction between the polymer and the material of the matrix, the viscosity of the
polymer, and the curing mechanism of the polymer. For this reason, low viscosity
polymers with a controllable curing reaction were chosen to map a predictive model for
the saturation of these porous materials. By incrementally exposing larger volumes of
this polymer to the porous matrix and recording the amount of volume the polymer
filled a predictive model was found.

ACKNOWLEDGE: Cooney-Jackman Endowed Professorship