Cost–effective additive manufacturing of metal parts using pneumatic extrusion: investigation of the sintering process

Purpose The purpose of this study is to develop a low-cost and efficient method for 3D printing CuSn15 bronze alloy parts using a pneumatic extrusion system. By avoiding complex processes such as filament preparation and solvent/catalytic debinding, the study aims to streamline the low-cost production process of metallic components while maintaining high mechanical performance. The research also seeks to evaluate the effects of different sintering temperatures and times on the mechanical properties of the printed parts. Design/methodology/approach A simple and cost-effective pneumatic extrusion system was designed to 3D print a metal paste containing CuSn15 alloy powders. The metal paste was prepared by manually mixing of CuSn15 powders, carboxymethyl cellulose and distilled water. The printed parts were subsequently dried and sintered at various temperatures and times to study the effects of these parameters on the material properties. Tensile test and scanning electron microscope analysis were conducted to assess the structural integrity and mechanical performance of the samples. Findings The study found that the pneumatic extrusion system enabled the successful 3D printing of CuSn15 bronze alloy parts without the need for complex processes. Increasing sintering temperature led to improved mechanical properties and decreased porosity. Increasing the sintering time at 820 °C led to a reduction in mechanical performance. The study demonstrated that the sintering parameters significantly influence the porosity and mechanical properties of the printed parts. Originality/value This study introduces a novel approach to 3D printing CuSn15 bronze alloy using a pneumatic extrusion system, eliminating the need for traditional filament preparation and solvent/catalytic debinding processes. The research provides new insights into the effect of sintering parameters on the mechanical properties of additively manufactured metal parts. By simplifying the production process, this study offers a low-cost, efficient method for producing complex-shaped metallic components, potentially expanding the applicability of 3D printing in industries such as electronics, marine and mechanical engineering.