Sustainability in additive manufacturing (AM) is about more than just energy efficiency. It starts with materials. At Atomik AM, we take a materials-first, solutions-focused approach, ensuring that sustainability is not an afterthought but a core part of the process.
One of the key drivers of sustainability in binder jetting additive manufacturing is the evolution of binder technology. Next-generation binders not only enable greater green part strength and process efficiency, but they also contribute to waste reduction, energy optimisation, and a more interconnected manufacturing ecosystem.
Why Binders Matter in Sustainable Manufacturing
In binder jetting, binders act as the adhesive that holds powder particles together before sintering or further processing. While much of the sustainability conversation in AM has focused on powder reuse and recycling, binders themselves play a crucial role in reducing waste, improving material efficiency, and enabling a more resource-conscious manufacturing process.
Key sustainability challenges in traditional binder systems include:
- Inefficient heat treatment steps that consume excessive energy
- Limited green part strength, leading to breakage and material waste
- High reliance on virgin powder, as many systems are not designed for reclaimed or non-conventional materials
- Lack of adaptability, making it difficult for manufacturers to optimise production without heavy investment in new equipment
A Smarter, More Sustainable Approach to Binder Jetting
At Atomik AM, we believe that binders should do more than just hold a part together. They should enhance material properties, optimise performance, and create a more sustainable production cycle. Our next-generation binders are designed to address common industry challenges while enabling manufacturers to reduce waste, lower costs, and improve part quality.
Enhancing Green Part Strength to Reduce Waste
One of the biggest inefficiencies in binder jetting is the risk of green part failure before sintering. If a part is too fragile, it may break during handling, leading to scrap, reprints, and increased material consumption. Our latest binder formulations improve green strength, reducing the likelihood of failures and ensuring a higher yield from each print run.
Controlling Microstructure for Improved Material Performance
Next-generation binders do more than just bind. They influence the final microstructure of the part, allowing for tailored mechanical properties that meet the specific needs of different industries. By controlling how powders interact at a microscopic level, Atomik AM is developing binder systems that enable greater part consistency, reduced defects, and enhanced final properties.
Enabling the Use of Recycled and Non-Conventional Powders
Traditional AM processes often demand highly refined, virgin powders, which come with a high environmental and financial cost. At Atomik AM, we are shifting this approach by integrating non-conventional aluminium powders from other sectors, reducing reliance on energy-intensive powder production. Our binders are formulated to work with a broader range of powders, helping manufacturers cut costs and minimise material waste.
Future-Proofing Existing Equipment
One of the biggest barriers to sustainable AM adoption is the need for significant capital investment in new equipment. Many customers are not ready to invest in an entirely new machine, and existing binder jetting systems often have limitations in binder and powder compatibility. Atomik AM is developing a universal binder solution, launching this spring, that will allow manufacturers to enhance their existing processes without costly hardware overhauls. By enabling greater flexibility in materials and formulations, we help manufacturers get more from their current systems while maintaining a high level of part performance and quality.
Building a More Sustainable Manufacturing Ecosystem
Sustainability in AM is not just about reducing energy use or minimising waste in isolation. It requires rethinking how materials, processes, and systems interact. Atomik AM’s approach to sustainable binder jetting is rooted in a broader ecosystem model, where companies collaborate to maximise resource efficiency.
By integrating waste powders from one industry into another, optimising material use through better binder formulations, and designing smarter, more adaptable manufacturing solutions, we are proving that sustainability and profitability can go hand in hand.
The Future of Sustainable Additive Manufacturing
The demand for greener manufacturing solutions is only growing, with industries like aerospace and automotive leading the charge in seeking more sustainable AM processes. However, true progress requires a shift in mindset. Sustainability should not be viewed as a compliance measure, but as a driver of innovation, efficiency, and long-term profitability.
At Atomik AM, we are committed to developing binder jetting solutions that enable manufacturers to produce better, stronger, and more sustainable parts. By rethinking materials, binder formulations, and manufacturing ecosystems, we are shaping the future of additive manufacturing one binder at a time.
Interested in Next-Gen Binder Technology?
If you are looking to improve your binder jetting process, reduce material waste, and enhance green part strength, get in touch with Atomik AM today.
