| Summary: | The high processing temperatures traditionally required for Additive Manufacturing
(AM) often degrade polymer powders, limiting part performance and recyclability. Reactive
Binder Jetting (RBJ), a novel AM process, addresses these challenges by utilizing
a dual-ink binding system that facilitates powder consolidation at ambient temperatures.
This eliminates the need for energy-intensive equipment, such as lasers or heaters,
enabling sustainable manufacturing of complex, functional parts.
This research focuses on the fabrication of polyurethane (PU) components using RBJ.
PU is highly versatile due to its tunable co-polymer structure, making it a valuable
material for applications ranging from insulation foams to biomedical implants. RBJ
challenges addressed in thesis include reliable ink jetting, maintaining stoichiometry and
achieving optimal saturation levels for part consolidation. To address these challenges,
all materials were characterised, inkjet printing parameters were optimised, and fully
consolidated, three-dimensional (3D) 'green' part tested.
The �ndings demonstrate RBJ printing is capable of forming robust polymer 'green'
parts, introducing potential applications within the biomedical or sports industries.
Through characterisation of reactive inks, control of droplet deposition strategies, and
validation via mechanical testing, this work establishes RBJ as a sustainable alternative
for polymer AM. The research highlights opportunities for future innovations, such as
expanding the range of printable materials, including sustainable inks and reactive
powders, improving RBJ printing process scalability, and developing multifunctional
components with gradient properties.
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