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Effect of saturation level on dimensional accuracy and binder migration of porous alumina ceramics via binder jetting 3D printing

  • Journal of the Korean Crystal Growth and Crystal Technology
  • Abbr : J. Korean Cryst. Growth Cryst. Technol.
  • 2026, 36(3), pp.124~130
  • DOI : 10.6111/JKCGCT.2026.36.3.124
  • Publisher : The Korea Association Of Crystal Growth, Inc.
  • Research Area : Engineering > Materials Science and Engineering
  • Received : July 15, 2026
  • Accepted : August 11, 2026
  • Published : September 30, 2026

Choi Jung Hoon 1

1한국세라믹기술원

Accredited

ABSTRACT

The effect of binder saturation level on the dimensional accuracy and binder migration behavior of alumina compacts fabricated by binder jetting three-dimensional printing was quantitatively analyzed. Spherical α-Al₂O₃ powder with D₅₀ = 5.07μm was printed at five core/shell saturation conditions of 100/200, 110/220, 130/260, 150/300, and 170/340 % using a ProJet 360 system. The X-Y dimensional deviation remained between 0.13 and 0.17 mm and showed no consistent dependence on the saturation level, whereas the Z-direction binder migration depth increased about 3.35-fold, from 0.184 to 0.616 mm, with increasing saturation. Surface roughness Rₐ and Sₐ correlated almost linearly with the Z-migration depth (R > 0.99). A Washburn analysis confirmed that the capillary infiltration time (about 7.4 ms) is far shorter than the layer drying time, so the migration depth is expected to increase in proportion to the dispensed binder volume. Relative to this proportional baseline, the migration depth increased linearly with saturation up to 150/300 %, then rose abruptly at 170/ 340 %, indicating an inflection between 150/300 % and 170/340 % that is attributed to percolation breakthrough.

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