Design and Manufacture of a Functional 3D-Printed Stirling Engine: A Case Study Involving Bound Metal Deposition of 17-4 PH

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Bound metal deposition (BMD) is a recently commercialized additive manufacturing of metal (AMM) process in which metal powder-binder composites are printed, debound, and sintered. Although potentially offering significant costs savings compared to traditional AMM process, BMD is poorly understood by designers and engineers. This research seeks to addresses this problem by designing and manufacturing a beta Stirling engine (BSE) using BMD of 17-4 PH. Best practices included under- and over-sizing features for post processing, reducing aspect ratios to less than 8:1, and designing for horizontally- printed features. FARO ScanArm data indicated that as- sintered dimensions were generally within 0.07 mm [0.003 in] of the as-designed dimensions with high-aspect-ratio features deviating up to 0.50 mm [0.020 in].

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Journal: TechConnect Briefs
Volume: TechConnect Briefs 2019
Published: June 17, 2019
Pages: 139 - 142
Industry sector: Advanced Materials & Manufacturing
Topics: 3D Printing, Advanced Manufacturing
ISBN: 978-0-9988782-8-7