Research progress on densification behavior of component fabricated by Binder Jetting additive manufacturing

Binder jetting (BJ), an additive manufacturing technology that constructs complex geometries via layer-by-layer selective deposition of binder to bond powder beds, is characterized by high production efficiency, exceptional material utilization, and excellent multi-material compatibility. This review systematically analyzes the BJ process chain, focusing on the influence of powder bed quality, binder properties, and post-processing procedures on density control and dimensional accuracy. By synthesizing recent research, we conclude that powder particle size distribution and morphology significantly affect the initial packing density of the powder bed. Additionally, binder rheology, binding strength, and thermal decomposition behavior critically govern green part structure and porosity, while optimized debinding and sintering processes during post-processing effectively reduce porosity and shrinkage rates. However, current challenges faced in BJ technology, including powder bed packing density, microscale droplet deposition accuracy, innovative binder system design, and dimensional stability control. To address these limitations, this paper proposes future research directions: developing high-performance specialized powders, designing environmentally friendly high-efficiency binders, and optimizing post-processing protocols. These advancements are expected to overcome existing density constraints and unlock BJ's potential for manufacturing high-performance complex components.