Grant: Applied Research Tools and Instruments Grants

Red Deer Polytechnic (RDP) uses a wide breadth of industrial manufacturing equipment and expertise centralized and dedicated to serving applied research for industry. This includes CAD/CAM, full industrial capacity metal fabrication facilities, polymer processing, polymer and metal additive manufacturing, materials testing and automation integration. Established in 2009 as the Centre of Innovation in Manufacturing (CIM), over 400 industrial projects have been completed to grow Alberta businesses. Since becoming a Technology Access Centre (TAC), service offerings have expanded to include design for manufacturing, validation, and manufacturing optimization. The project aims to investigate and optimize the binder jetting process for ceramics and high alloy steels using the additive manufacturing equipment currently at RDP’s CIM-TAC. The current system (ExOne Innovent+ binder jet 3D printing process) holds immense potential for various industrial applications, including but not limited to aerospace, automotive, and healthcare, due to its open-source material capability and the ability to produce complex geometries. However, the success of binder jetting is intricately tied to the microstructure and porosity of the fabricated components, which directly influence densification. Understanding the microstructure and porosity of binder jetted materials is paramount for ensuring the mechanical, thermal, and chemical properties meet industry standards. Ceramics and high alloy steels are particularly challenging to fabricate using 3D printing due to their unique material characteristics. Understanding the microstructural evolution during sintering is crucial for achieving higher densities and enhanced mechanical properties. The demonstrated need for the proposed optical microscope and metallurgical sample preparation equipment is rooted in the specific challenges and intricacies of researching 3D printing binder jetting technologies, particularly with a focus on ceramics and high alloy steels using the ExOne Innovent system. The unique characteristics of these materials demand a comprehensive understanding of their microstructure and porosity. The optical microscope and sample preparation equipment will enable measurements that lead to the optimization, advancement of knowledge and commercialization of binder jetting products and processes. They also enhance the teaching and learning of students and the community.