Friction-Induced Distortion in Binder Jetted 316 L Stainless Steel: Experimental Analysis, Simulation, and Compensation Strategy

This study investigates the origin of distortion during sintering of 316 L stainless steel components produced by binder jetting, focusing on friction between the sample and the support surface and on density inhomogeneity in the green state. A design of experiments (DoE) approach evaluates the influence of key printing parameters on the sintering behavior of two geometries with different through-hole sizes. Dimensional measurements, and density profiling, are performed in both green and sintered states. Sintering simulations use the Skorokhod-Olevsky viscous sintering (SOVS) model and include experimentally measured density gradients and frictional effects. Results show that green density varies significantly (52% to 58%) depending on printing parameters, especially binder saturation, and exhibits directional dependence. These variations lead to measurable distortions during sintering. Simulations that include both friction and density gradients match experimental deformations with deviations below 4%. A compensation strategy that places parts on co-sintered 316 L support plates with interposed refractory particles reduces distortion to <1.5%. This work demonstrates the combined role of friction and density gradients in sintering distortion and presents a practical method to improve dimensional accuracy in binder jetting.