Assessment of Microchannel Architectures Accuracy in Stainless Steel 316L/Red Mud Composite Parts Fabricated by Binder Jetting

This study investigates the accuracy of microchannels fabricated using binder jetting. The research aims to contribute to the future development of continuous-feeding anodes for direct carbon fuel cells (DCFC) within the framework of the PRIN PNRR JETCELL project. The anodes are engineered with tailored microchannel architectures to maximize surface area to improve the electrochemical efficiency, facilitate the electrolyte flow, and prevent the fuel leakage. Stainless steel 316L and red mud composites were employed, as stainless steel provides high mechanical properties, while red mud enhances sustainability and functionality for anode applications. By systematically varying microchannel dimensions and spacings, the manufacturability and structural fidelity of micro-scale features critical to device performance have been assessed. Dimensional analysis, conducted via confocal microscopy, reveals key insights into shape retention and dimensional accuracy. To address sintering-induced shrinkage and dimensional deviation induced by printing process, scaling factors law as a function of nominal channel size have been proposed, paving the way for more predictable and precise fabrication of advanced functional components.