Simufact, part of Hexagon's Manufacturing Intelligence Division, has launched simulation software for metal binder jetting (MBJ) processes. For the first time, manufacturers have the possibility to recognize and prevent the deformation of parts caused by the sintering process already in the design phase. The new module in Simufact Additive supports users of MBJ technology in achieving the required product quality and at the same time utilizing the advantages of the process for high-volume production.
Metal Binder Jetting is an innovative additive manufacturing technology that offers decisive advantages compared to conventional powder bed processes:
- High quantities with minimal spacing per printing process
- No support structures required
- Higher printing speed compared to conventional AM processes
MBJ offers users the potential to replace low-cost, low-volume metal injection molding for everything from automotive and aircraft parts to medical applications. As high resolution is possible, costs and lead times can be reduced for the production of complex and lightweight metal parts such as gears or turbine wheels.
Users can quickly gain knowledge of the benefits of the solution in order to get the most out of it. One of the biggest challenges in the MBJ process is the prediction of shrinkage during sintering. In the sintering process, the so-called green parts are heat-treated and can shrink by up to 35%. Simple shrinkage models cannot predict such distortions during the sintering process. Until now, costly physical tests were necessary to optimize the pressure of each part. This prevented many manufacturers from taking advantage of the cost savings and flexibility that MBJ offers.
With the new MBJ tool, the user is able to predict shrinkage caused by factors such as thermal stress, friction and gravity during sintering, even without specialized simulation knowledge. Components can be virtually printed, analyzed and optimized during the design phase. This significantly reduces the number of misprints. Sinter-induced mechanical stresses are predicted in the simulation and possible defective areas are detected before the actual print. The user uses this information to make early changes in product development and reduce costly redesigns.
Simufact Additive has a simple and practical GUI design that automatically sets up the MBJ process and provides the required CAD/CAE files for real printing. In addition to the simulation of individual MBJ processes, Python scripts can be used to automatically create and calculate a large number of variants, such as from a test plan. To validate the sinter compensation and ensure quality, the optimized geometry of the MBJ tool can be directly compared to both the original design geometry (CAD) and a scan of a manufactured part within the user interface.
"We are excited to bring the first Metal Binder Jetting sintering process simulation solution to the market. We know that metal binder jetting is a key manufacturing technology for our customers, especially where complex parts need to be produced in high volumes, such as in the automotive industry. This development was only possible through close collaboration between our manufacturer and printer partners and our highly experienced research and development department," says Dr. Gabriel McBain, Senior Director Product Management, Simufact & Forming Technologies.
