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The prosthetic arm produced by the binder jetting process reduced part count and weight.


facility expects to increase annual production from 1,000 to 40,000 by 2020. “We spent years proving out this


technology for a critical component in the heart of the engine,” said Greg Morris, general manager, GE Aviation, of the nozzles, which will reduce weight by 35% and parts from 18 to one. “Now we are well positioned to apply this technology to other components in the same harsh environment which could prove to be game-changing for fu- ture engine programs and designs.”


Alternative Approaches


T ough powder bed fusion is the most utilized process, a variety of 3-D-printing methods using metal are on the market. One alternative is directed energy deposition, which de- posits wire or powder into thin layers that are then melted using an energy source. Unlike powder bed fusion, though, directed energy deposition often requires additional processing to improve surface fi nish. Binder-based jetting systems is another 3-D-printing process, which is similar to techniques already familiar to metalcasters in the production of cores and molds. T e process features a print head selectively spraying a binder solution over a metal powder bed. T e layer is dried with a heating lamp and then a new layer of powder is spread on top. T is process repeats until the object is fully formed. T e object is carefully removed from the non-bonded metal powder and placed in an oven to fully cure the binder. T e fragile part then


is placed in a kiln where it’s infused with bronze powder to create a highly solid metal matrix component. “Really what we print is a ma-


trix, instead of an alloy,” said Bernie Potts, sales manager, ExOne, Troy, Michigan. “For example, it could be 60% stainless steel with 40% bronze infi ltrated into it. Using this process, we’re able to produce components


with 97 or 98% density.” The capabilities of a binder jet-


ting system can be seen in a case study featuring a medical prosthetics manufacturer looking to improve production of a component used in a prosthetic hand. The components printed in a stainless steel/bronze matrix reduced weight and integrat- ed multiple pieces into a single as-


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Photos courtesy of ExOne


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