3DP process for fine mesh structure printing

Three dimensional printing (3DP) is a unique technique for creating complex shapes. However, printing feature sizes at less than 500 μm with high integrity and intricate structures have not been possible. In this study, TiNiHf shape memory alloy (SMA) powder was printed into 3D mesh structures of 300 μm wire width. Effects of printing layer thickness and binder saturation level on the integrity and dimensional accuracy of the 3D mesh structures were evaluated. 35 μm printing layer thickness and 170% binder saturation level offer the highest mesh structure integrity. Also, 35 μm printing layer thickness results in the smallest dimensional deviation from the designed 200 μm mesh width with the smallest standard deviation. Overall, 35 μm printing layer thickness and 170% binder saturation level are the most preferred printing condition for the designed 3D mesh structure.