Binder Jetting

    3D Printed Binder Jet Parts

    Wall Colmonoy offers 3D printed parts, manufactured on the Desktop Metal Shop System™.  We produce parts with superior surface finish and resolution versus laser-based 3D printing systems at a competitive cost.

    The Wall Colmonoy Additive team will provide advice to advance complex manufacturing schemes, using state of the art modelling technology and experience as the UK’s first machine shop to adopt the Shop System™.

     

    Request a Quote

     

    Advantages

    High Speed

    With high-speed, single-pass print technology, we can produce high-quality metal parts at high speed- meaning hundreds of metal parts per day.

    Superior Print Quality

    Our system produces high-resolution parts with incredibly fine feature detail. Surface finishes as low as 4µm Ra out of the furnace, and <0.1µm Ra with mass finishing are possible.  Components are fully dense, solid parts, no debind or infill required.

    High resolution

    Our binder jet technology features high resolution prints. With 1600×1600 DPI native, and over 670M drops per second, we deliver high-speed, high-resolution 3D printing.

    Flexible manufacturing

    Wall Colmonoy can cost effectively 3D print low-volume batches of complex parts due to elimination of tooling. We produce hundreds of near-net-shape parts every day with dramatically reduced labor costs and expanded geometric flexibility. We can respond quickly to the need for variations and improvements.

    Fewer steps

    Reduce the complexity of making a part. Parts that previously required multiple steps can now be produced in one, avoiding the costs of complex assembly.

    Less waste

    Improve your environmental footprint, using only what is needed for the final part. Binder jet parts have zero waste, as left over powder is reused.

    Design freedom

    Create internal channels, thin walls, overhangs, unsupported arms and curved surfaces to make the most of the design freedom offered by additive manufacturing.

    Reduced inventory

    Instead of holding a vast inventory of thousands of products- print what you need at the time when you need it. The responsiveness of our binder jetting system means you can have a part printed within a few days.

    Cast vs. Printed Components

    Knives for aseptic packaging

    Cast components typically only make sense when producing at volume, due to the costs of developing tooling.  3D printed components can be produced in small to medium volumes without any tooling costs, which is useful for replacement parts or low volume runs which are traditionally hard to source.

    The properties of a printed part usually meet the properties achieved with a cast part. Parts printed on the Shop System™ are typically 95% dense.

    Cast vs. Printed Properties Comparison: 17-4PH
    Standard Shop SystemH900 Heat Treat Cast H900 Heat Treat Shop System™ As Sintered
    Yield strength (Mpa) ASTM E8M 981 ± 50 1000 660 ± 40
    Ultimate tensile strength (MPa) ASTM E8M 1205 ± 35 1170 912 ± 35
    Elongation at break (%) ASTM E8M 11.9 ± 5 5 5.9 ± 2
    Young’s modulus ASTM E8M 185 ± 20 190 178 ± 30
    Hardness (HRC) ASTM E18 40.5 ± 2 41 26.4 ± 1
    Density (g/cc) ASTME B311 7.5 -7.66 7.8 7.5 ± 7.99

     

    3D printed components are more suitable for iterative design. Changes can be made and printed in the same day, allowing flexibility and innovation in the design process.   A large part of the cost of a cast part is sunk into tooling which can be expensive to design and develop- so making a change will often require that tooling is redesigned, resulting in mounting costs.  With a cast part, designers sometimes need to sacrifice design features in order to achieve ease of manufacture.

    Print specifications

    Wall Colmonoy Additive team are excited to discuss your latest 3D printing project.  To discuss part suitability contact us.

    Print Technology Binder Jetting
    Print direction Uni-directional
    Maximum throughput 800 cc/hr
    Layer thickness 50 µm – 100 µm
    Binder jetting module 70,000 nozzles (5x redundancy)
    Dimensional tolerance of parts ± 3.0%
    Native printhead resolution 1600 dpi (1 pL native drop size)
    Build Envelope 8L
    350 x 222 x 100 mm (13.8 x 8.7 x 3.9 in)
    Optimum part size For best results during printing and sintering, we recommend limiting the part size to 150 x 100 x 50 mm.

     

     

    Finishing

    Parts can be supplied as printed, or surface polished.

    Test pieces showing finish as sintered and polished using electo / vibratory polishing.

    Materials

    The Shop System™ currently prints in 17-4 PH, IN 625 and 316L.  Wall Colmonoy alloys for the Shop System™ are under development, including cobalt-based Wallex® and nickel-based Colmonoy® alloys. Contact us for further information.

    Part Gallery

    • Three Wheeler Part
      Three Wheeler Part
    • Bottle Opener
      Bottle Opener
    • Aseptic Knife
      Aseptic Knife
    • Pump Component
      Pump Component
    • Neck Ring
      Neck Ring
    • Homogenizer Valve
      Homogenizer Valve
    • Atomization Nozzle
      Atomization Nozzle
    • Chemical symbol for love 3D printed on our high resolution binderjet system
      Chemical symbol for love 3D printed on our high resolution binderjet system

    About Binder Jetting

    Our Desktop Metal Studio System uses a simple 3-part process to deliver high quality finished parts.

    Step 1: Print

    For each layer, the printer spreads metal powder across the build bed, and precisely jets a binding agent to bond loose powder and define part geometry. Layer by layer, metal powder and binder is deposited until the entire build volume is packed with bound parts and surrounding loose powder.

     

    Step 2: Depowder

    Once an entire build is complete, the build box is removed and placed in a powder station for bulk and fine depowdering—with the help of a hand-held air pick. Loose powder is removed from the parts and recovered via a built-in powder recycling system with powder sieving.

     

    Step 3: Sinter

    Depowdered parts are placed onto trays in a shop-safe, high-throughput furnace for batch sintering. With an external gas hookup and temperatures reaching 1400ºC, the Shop System™ furnace is able to deliver quality and reliable sintering in a shop-friendly format.

     

    We’re here to help!

    Contact Us

    CONTACT
    Wall Colmonoy Limited
    Alloy Industrial Estate
    Pontardawe, Swansea,
    Wales (U.K.) SA8 4HL
    E: additivemanufacturing@wallcolmonoy.co.uk
    T: + 44 (0) 1792 862287

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    COVID-19 RESPONSE
    All Wall Colmonoy operating locations, including Franklin Bronze Precision Components, remain open as we support “essential business” for critical industries.
    Read about our response to COVID-19. Wall Colmonoy Corp (USA) and Aerobraze | Wall Colmonoy Limited (UK) | Franklin Bronze Precision Components