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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Additive Manufacturing Modeling, Simulation and Artificial Intelligence
Presentation Title F-35: Optimization of Binder Jet Printing Parameters of an Irregular, Non-Spherical Copper Powder Manufactured Via Solid-State Machining and Comparison to a Simplified DEM Simulation
Author(s) Mahsa Beyk Khorasani, Eric Rhodes, John E. Barnes, Markus Chmielus
On-Site Speaker (Planned) Mahsa Beyk Khorasani
Abstract Scope The effects of binder type, binder saturation, layer thickness, roller traverse speed and roller rotation speed on the surface quality and dimensional uniformity of binder jet printed copper parts were studied. Irregular, non-spherical copper powders were printed using varying binder saturation levels (30%–60%) and layer thicknesses (150–250 m). Roller dynamics were systematically altered to evaluate their influence on powder bed topography. Surface unevenness was characterized using profilometry, revealing higher waviness and roughness at both low and high saturation levels due to fragile layer cohesion and lateral binder bleed, respectively. Optimal saturation near 40% and layer thickness of 200 m produced minimal topographical variance. Higher roller rotation speed combined with lower roller traverse speed resulted in the highest green density as has been proved by Discrete Element Modeling (DEM) simulation via Rocky software. Regarding binder type, solvent-based binder resulted in higher green density, about 4%, compared to water-based binder.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Powder Materials,

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F-22: An Artificial Neural Network Modeling Approach to Electroforming of Micro-Tubes in the Presence of Surfactants
F-23: Computational Thermodynamics-Based Optimization of Ti-6Al-4V via Al and V Substitution for Additive Manufacturing
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F-25: Creep Property of SS316L Lattices Fabricated by Laser Powder Bed Fusion
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F-27: Expanding Capabilities to Simulate Powder Bed Fusion Process With Additive Manufacturing Module
F-28: Experimental‑CFD-Based Observation of Thermo‑Fluid Mechanisms in LPBF with Nanoparticle‑Coated Powders
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F-33: Modeling and Simulation of the Shock Response in AM Material Accounting for the Retained Porosity
F-34: Numerical Analysis of the Flow Behavior in the Mold Induced by a Real Clogged Nozzle and Symmetrically Reduced Nozzles
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