Binder Jetting Machines: In-Depth Guide to Types, Uses, Benefits, and Limitations

Anyone interested in the benefits and fantastic results of additive manufacturing has a long list of methods to choose from. One that’s worth noting in the mix is binder jetting, which mixes the worlds of liquids and powders to make printed products for the art, aerospace, medical, and industrial sectors (and then some).

For those not quite familiar with binder jetting, we’ll go into more detail about what the process entails, its downsides and upsides, and what applications it’s usually best for.

What Is Binder Jetting (BJ)?

Binder jetting (or BJ) is one of the many 3D printing technologies out there, but more specifically it functions by using an industrial printhead to combine and bond a liquid agent and powder. It can print sand, metal, composite, and ceramic parts in this way and is perfectly capable of creating high-quality builds. Two examples of systems, machines, and software that exist out there are ProJet MJP 5600 from 3D Systems and J5 MediJet from Stratasys.

How Does Binder Jetting (BJ) Work?

Let’s go a little more in-depth with how binder jetting works. The steps for printing a part with binder jetting are:

First, you’ll create a CAD file of your design. This will then get sliced and send instructions to the binder jetting printer in the correct sequence.
Then, a roller will coat the build platform in an even, thin layer of powder.
Next, the printhead moves around, applying the liquid binder adhesive onto specific areas of the powder based on the sliced file of the object.
The build platform is then lowered by the thickness of one layer.
Another layer of powder is spread around by the roller and the same steps happen again, with the binding agent being dropped down onto specific parts of the powder. This happens layer by layer until you have your finished product.
Once it’s finished, any powder that wasn’t used will be left over and cleaned off the build platform.

What Are the Advantages of Binder Jetting 3D Printing?

Here are some of the perks of using binder jetting printing over other methods:

Capable of creating builds with precise dimensions
Works at room temperature (which helps cut down on warping and residual stresses
You can create both large and small builds with BJ
It’s a lot faster when you compare it to other 3D printing techniques
It’s more affordable and energy-efficient than laser models
Materials like ceramic and metal powders tend to be cheaper
The unbound powder serves as a natural support and gives more flexibility and less waste
Any unused powder can be repurposed for future print jobs

What Are the Disadvantages of Binder Jetting 3D Printing?

Although it has a decent list of advantages, there are also some downsides to be aware of with binder jetting:

Metal builds made with binder jetting can have higher porosity and lower mechanical properties
It’s not always an option for structural parts
In their “green” state, parts can be brittle
Post-processing is almost always required, which lengthens the timeline
Binder jetting is usually more low-resolution than other 3D printing methods

What Is the Process of Binder Jetting (BJ)?

The steps for printing a part with binder jetting are as follows:

Create and slice a CAD file of the part. This file is then used to send instructions to the printer in the correct sequence for the part to be printed.
The build platform is covered with a thin layer of powdered material, which is evenly distributed using a roller.
The printhead applies the binder adhesive selectively onto the powder where it is needed, based on the sliced file of the object.
The build platform is then lowered by the thickness of one layer.
Another layer of powder is spread over the previous layer. The powder particles are then bound together by the liquid binder, forming the object. This process is repeated layer by layer until the entire object is created.
Any unbound powder remains in place around the object. This is removed in the post-processing steps.

What Are the Types of Binder Jetting (BJ)

The type of binder jetting machine you’ll use depends on what binding agent and powder are used. Some common types of binders used in binder jetting include:

Polymer Binders

Polymer binders are usually paired up with ceramic powders and can be taken off with heat treatment. They have a lower viscosity and apply pretty easily through BJ printing.

Water-based Binders

You’ll find these binders working in tandem with sand or other mineral powders. They’re more environmentally friendly and can be easily removed through drying or sintering.

Solvent-based Binders

Solvent-based binders work best with metal and ceramic powders, and they can be removed through a process aptly named solvent debinding. They have a high solid content and are a breeze to apply to the bed.

Furan Binder

Furan binders are created with furfuryl alcohol and often get used with sand powders to make molds and cores for casting, especially more complex designs. They have good mechanical strength and thermal stability and can be cured by heat or acid catalysts. You can strip the molds pretty easily from the casting.

Silicate Binder

Made from sodium silicate or potassium silicate, these binders are another option when it comes to casting and work well with sand powders (and are great for ferrous metals once the mold has been made). They have good refractory properties and have no problem with high temperatures. They get cured through drying or by adding an acid catalyst.

Phenolic Binder

Another option for casting purposes is phenolic binders (made from phenol-formaldehyde resins). They have good mechanical strength and dimensional stability and can be cured by heat. They’re fantastic if you need high-strength, high-temperature products.

UV Binder

You’ll need access to a UV light for this type of binder and they don’t work with many materials (photopolymer resins are best), but they do produce high-resolution and complex parts.

What Materials Can Be Used for Binder Jetting (BJ)?

There are many materials you can use for binder jetting. Here’s a rundown of the main types:

Metals: Stainless steel, titanium, aluminum, and copper, which create parts with high strength and durability.
Ceramics: Tiles, sanitary ware, and insulators, using materials like alumina, zirconia, and silicon carbide.
Sand: Mixed with a binder (like furan, silicate, or phenolic) to make molds and cores for foundry casting.
Plastics: Powders like polyamide, polypropylene, and polycarbonate to make consumer goods or parts for the automotive and medical industries.
Composites: Carbon fiber and glass fiber mixed with a polymer binder.

To learn more, see our full guide on 3D Printing Materials.

What Are Examples of Binder Jetting 3D Printing?

Below are some examples of binder jetting 3D printing systems:

ProJet MJP 5600 from 3D Systems.
J5 MediJet from Stratasys.

What Are the Applications of Binder Jetting?

There are so many uses for this kind of 3D printing, and this condensed list only covers a small portion of them:

Prototypes
Aerospace components
Casting patterns
Jewelry
Full-color decorative objects
Cores and molds
Tooling

FAQs on Binder Jetting

How Much Does Binder Jetting Cost?

Typically, binder jetting machines cost upwards of $100,000. For business owners and manufacturers this is often pretty economical since these printers don’t use as much power and use cheaper materials.

Is Binder Jetting a Fast 3D Printing Process?

Yes, in fact, binder jetting is often considered the fastest 3D printing technology. It can produce high volumes in a shorter period of time without losing out on precision.

Does Binder Jetting 3D Printing Require Support?

No, binder jetting typically doesn’t need any kind of additional support structures because the powder that’s rolled onto the print bed offers this already. This means that several parts can be printed at the same time on the same powder bed, which is ideal for low-to-medium batch production.

Does Binder Jetting Only Work With Metals?

No, binder jetting works with far more materials than just metals. You can also print with sand, ceramics, and some polymers.

Kat de Naoum

Kat de Naoum is a writer, author, editor, and content specialist from the UK with 20+ years of writing experience. Kat has experience writing for a variety of manufacturing and technical organizations and loves the world of engineering. Alongside writing, Kat was a paralegal for almost 10 years, seven of which were in ship finance. She has written for many publications, both print and online. Kat has a BA in English literature and philosophy, and an MA in creative writing from Kingston University.