Physicochemical Limitations of Capillary Models Applied to High-Concentration Polymer Solutions

[Image: see text] Advances in binder jet printing (BJP) require the development of new binder–powder systems, for example, to increase compatibility with better performance metal alloys or to increase the strength of parts using stronger binders. The dynamics of binder absorption are principally understood through capillary models. However, validation of these models in BJP has focused on variation of powder properties. Using a design-of-experiments approach and an optical observation method to track absorption of droplets, this study tests the influence of fluid properties on absorption time against the predictions of capillary models. Properties specific to polymeric binders, such as molecular weight and entanglement state, are also considered. Capillary models are found to be generally accurate in predicting absorption time in dilute systems; however, these predictions are not accurate for highly concentrated binder solutions. The effect of polymer entanglement becomes prevalent as the solution concentration increases, which can also potentially occur as a result of increased evaporation due to powder bed heating. Specifically, concentrated solutions close to the onset of entanglement will absorb much more slowly than predicted. Future models of BJP systems must account for the possibility of polymer entanglement throughout the absorption process. Improved models will provide a more accurate understanding of the flow and solidification of the binder in the powder, allowing faster development of new binders for improved performance in printing.