Binder jetting has rapidly evolved into one of the most scalable and cost-effective additive manufacturing (AM) processes. But as demand for complex geometries, high-strength parts, and new material applications grows, so does the need for advanced binder solutions. Traditional binders have served the industry well, but they are often limited by material specificity. Now, a new wave of universal and next-generation binders is set to transform what’s possible in binder jetting.
Atomik AM is at the forefront of this transformation, working on cutting-edge binder technologies that will give manufacturers more flexibility, greater efficiency, and access to materials previously considered too challenging for binder jetting.
Why Binder Choice Matters in Binder Jetting
The binder in a binder jetting process is more than just an adhesive—it dictates green part strength, influences sintering outcomes, and directly impacts production efficiency. The wrong binder for a given material can lead to weak green parts, inconsistent densities, or poor final mechanical properties.
Historically, binder development has been material-specific. Manufacturers had to source different binders for different powders, often requiring process adjustments and extensive testing to ensure compatibility. This approach has worked, but it introduces inefficiencies, especially for those looking to scale up production or introduce new material systems.
The next evolution of binder jetting moves beyond these constraints. Universal binders and second-generation material-specific binders are unlocking new applications, streamlining workflows, and making binder jetting a more powerful tool for advanced manufacturing.
What Makes Universal Binders Different?
A universal binder is designed to work across multiple material systems, removing the need for unique formulations for different metal powders. This development could have major implications for manufacturers, particularly those working with a range of materials or looking to switch between materials without overhauling their entire process.
While Atomik AM has not yet launched its Universal Binder, the work being done in this space reflects the growing need for more adaptable solutions. The benefits of a universal binder could include:
- Increased efficiency – Simplifying inventory management by reducing the number of different binders required.
- Enhanced process consistency – Standardising binder jetting workflows across different powders, reducing the need for material-specific tuning.
- Stronger green parts – Improving part integrity before sintering, which is crucial for reducing defects and increasing yields.
For manufacturers using multiple material systems, the potential of a universal binder is clear. The ability to consolidate binder formulations without compromising performance could reduce waste, lower costs, and accelerate new material adoption in binder jetting.
Next-Gen Binders: Unlocking Aluminium, Copper, and More
While universal binders provide flexibility, certain materials still require specially engineered binder systems. This is particularly true for metals like aluminium and copper, which present unique challenges in binder jetting.
Why Aluminium and Copper Need Specialised Binders
Aluminium is a highly sought-after material for its lightweight properties, corrosion resistance, and strength-to-weight ratio. However, its high oxidation potential and sintering characteristics make it difficult to process via binder jetting without a binder optimised for the material.
Copper, on the other hand, offers excellent thermal and electrical conductivity, making it ideal for applications in electronics, energy, and heat management. However, its sintering process requires careful binder selection to ensure uniform densification and minimise porosity.
Tailored Solutions for Challenging Materials
Atomik AM is developing second-generation binders designed specifically for materials like aluminium, copper, and other advanced metals. These new formulations aim to:
- Optimise powder adhesion – Ensuring better layer cohesion during printing for improved green part strength.
- Improve sinterability – Reducing the risk of defects during densification, leading to higher-quality final parts.
- Enhance surface finish and mechanical properties – Enabling manufacturers to meet industry-specific performance requirements.
By engineering binders that align with the specific properties of these materials, Atomik AM is making binder jetting a viable solution for applications that demand precision, strength, and repeatability.
The Future of Binder Jetting: Beyond One-Size-Fits-All
The shift toward universal and next-gen binders marks a turning point for binder jetting technology. As manufacturers push the boundaries of what can be achieved with additive manufacturing, the need for binders that offer both flexibility and material-specific optimisation has never been greater.
Atomik AM continues to drive binder innovation, ensuring that manufacturers have access to solutions that support not only current production needs but also the future of additive manufacturing.
What’s Next?
While the Universal Binder is still in development, the impact of new binder technologies on binder jetting is already clear. Whether through universal solutions that simplify workflows or tailored binders that unlock high-performance materials, the industry is moving toward a future where binder choice no longer limits innovation.
If you’re interested in how advanced binder solutions can optimise your binder jetting process, get in touch with us to learn more.
