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In a project jointly funded by Ford Motor and ExOne, developers have now developed and applied for a patent for fast and reliable binder jet 3D printing and aluminum sintering, with performance comparable to die casting.
Although some aluminum alloys can already be 3D printed with lasers today, this process is slower than the new processes developed by Ford and ExOne. The new process is expected to increase Ford's efficiency, allowing the company to produce complex parts designed for additive manufacturing in an economical manner, thereby achieving size and weight reduction, part integration and performance improvements.
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"This is a breakthrough in manufacturing 3D printed and sintered parts for the automotive industry," said Harold Sears, Ford's head of additive manufacturing technology. "Although the 3D printing process is very different from stamping body panels, we have a better understanding of the behavior of aluminum today and its value in light vehicles. High-speed aluminum 3D printing paves the way for other opportunities that we are just beginning to consider because It used to be impossible to make complex parts from aluminum. This really opens the door to other opportunities."
ExOne CEO John Hartner (John Hartner) said: "Developing a fast, economical and simple method to 3D print aluminum with traditional material characteristics is a step towards lighter weight and more products and a more sustainable future. A critical step." "Our world-class engineers and scientists focus on solving the most difficult problems with 3D printing technology. This achievement is a real victory for all of us."
The new innovation comes from the adhesive jetting process, which is widely regarded as the fastest metal 3D printing method for high-volume output. It uses digital files to quickly ink-jet adhesives into a bed of powder particles such as metal, sand or ceramics to create a solid part, one thin layer at a time. When printing metal, the final bonded metal part must be sintered in a furnace to fuse the particles into a solid. The heating process enhances the strength and integrity of the metal. Although the sintering process of stainless steel is well known, achieving a high density greater than 99% is a breakthrough in the aluminum industry.
The Ford-ExOne joint development project was launched for the first time in 2019, and Ford led the final material and repeatability testing to verify its accuracy. The cross-functional Ford-ExOne team is actively working on designs using new materials and new processes.
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