Assembly Automation

Method for characterization and enhancement of 3D printing by binder jetting applied to the textures
quality
Gardan Julien
Article information:
To cite this document:
Gardan Julien , (2017)," Method for characterization and enhancement of 3D printing by binder jetting applied to the textures
quality ", Assembly Automation, Vol. 37 Iss 2 pp. -
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http://dx.doi.org/10.1108/AA-01-2016-007
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 Method for characterization and
enhancement of 3D printing by
binder jetting applied to the
textures quality
1. Introduction
Since the appearance of rapid prototyping and
more generally Additive Manufacturing (AM) in
the 1980’s, different technologies appeared on the
market (Wang and Zhang, 2012). There are several
available technologies based on this additive
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machining concept (Wohlers and Caffrey, 2013):
stereolithography (SLA), photo-masking, Selective
Laser Sintering (SLS), Fused Deposition Modeling
(FDM), 3D printing. Researchers work mainly on
the effect of model direction, slicing strategy, inside
optimized structure, scaffold development, save
material to improve cost, product quality, and
manufacturing time.
However, the quality and precision of the
different AM systems have not been definitely
established (Campbell et al., 2002; Xu et al., 1999)
to characterize the texture quality of product
manufactured by binder jetting in 3DP. Using an
inkjet technology with the 3D Printer (Projet 460
Plus), a first study observed a difference in the
printing quality depending strongly on the printing
direction. This manufacturing by inkjet implies a
decrease of the texture quality printed and mainly
on its outline. In this research, the texture is the
appearance of the printed picture, determined by the
material used, the ink applied and the chosen
manufacturing technology. The term texture is used
to describe the three-dimensional texture of the
printed surface depending on the manufacturing
process. The study examines the specimen texture’s
contours to assess the printing quality, using a text
as a first step. Observing a shape alteration of the
printed image, the research used the image
processing method to find how to modify the
model. The object orientation influences the texture
quality of its 3D printing according to the
projection of inkjet which is perpendicular to
building platform. The method is based on trial
printings and predefined specimens, while
measuring photographically their singularities with
an image comparison. A flowchart presents the
technical procedure from the 3D printing to the
measurement of the image distortion through the
high definition photography and an image
processing (Annex3.). The results will be presented
on a sample which is used to check more
information. It is essential to establish methodology
to capitalize the data and lead the study in order to
implement the model. This work uses a DFM
(Design For Manufacturing) approach to adapt the
original model and get a manufactured model close
to the desired texture. One of the major interests of
this approach is to obtain a better product, more
consistent with the original design. After an
analysis of results, the article will present the
prospects founded on the same method and the first
cases of study.
2. Review and methodology
2.1 3D Printing technologies
3DP – Three-Dimensional Printing, also known
as binder jetting, combines raw powder material
and binders. 3DP was invented in the late 1980s by
an MIT student named Paul Williams and his
advisor Professor Eli Sachs (Lipson and Kurman,
2013). Among the main advances that this process
brings to product development are the time and cost
reduction, human interaction, and consequently the
product cycle management (Ashley. S, 1991). The
binder jetting is an Additive Manufacturing process
in which a liquid bonding agent is selectively
deposited to join powder materials (Standard and
others, 2012). In 3DP by binder jetting, each layer
is created by spreading a thin powder layer with a
roller inside a manufacturing tray and the powder is
selectively linked by a printing head containing an
array of binder fluid jets (Fig1). The prototype is
removed from the powder bed because the part is
surrounded powder (Lu et al., 2009). However, the
structure in powder is not strong enough to be used
directly and need to be infiltrated by a resin to
densify the matrix. This technology has been used
to manufacture different ceramic or polymer
product with a wide range of applications (Moon et
al., 2001). 3DP can print in multicolor directly into
the part during the build process from a color
cartridge. The infiltrate improves the color
definition and the mechanical behaviors. Here, the
resin used is named ColorBond. This infiltrate used
as finishing agent was epoxy resin based and
cyanoacrylate. 3DP can provide architects or
designers a useful tool to quickly create a realistic
model. Functional products are feasible but the
Page 1 sur 9
 mechanical strength is low as shown in the
following data (manufacturer data from VisiJet PXL
Core powder after infiltration with the ColorBond
resin):
- Tensile strength : 14,2 MPa ;
- Elongation at break : 0,23% ;
- Modulus of Elasticity : 9,450 MPa ;
- Flexural Strength : 31,1 MPa.
3DP technology is used to assess the inkjet printing
quality according to different manufacturing
directions. In the study, the ProJet 460 Plus (3D
Systems) has produced the models in order to
assess the manufacturing behaviors (Fig 1.).
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Fig 1. 3D Printer manufacturing chamber
A powder hopper provides the manufacturing tray
in hydraulic powder (a Calcium Sulfate
Hemihydrate (like gypsum) with a very fine grain
size) by spreading through a roller. The printing
head projects droplets of the binder and the inkjet
color upon the raw powder bed. The texture quality
can be different in down or up surfaces due to the
color layers build over unbound or bound powder
managed by four separated bins of binders (clear,
cyan magenta, yellow) on the former 3D Printers
(ZCorp). The new 3D Printers (like the Projet 460)
use a single inkjet cartridge (HP11) to project the
clear binder on powder bed and a single inkjet color
cartridge (HP57) to superpose directly the color
upon the bound powder while reducing the previous
problem. The manufacturing process is influenced
by the powder spreading with a density gradient
and the scanning of the printing head. These
constraints create a behavior specific to product and
it has consequences on the product use. The effects
of printing orientations influence the surfaces
quality printed by 3DP and there are no
investigations to improve it.
2.2 Inkjet problems from 3D printing
Inkjet problems from 3D printing can be
observed depending on product orientation in
manufacturing. In practice, the 3D printing
produces a visual difference on the product surfaces
when it implies textures. This difference is due to:
- The grain of the surface caused by powder
(powder is the VisiJet PXL Core);
- The projection of ink droplets on the oriented
surfaces of product.
There are a lot of details that change with the
product orientation. The granular surface remains
homogeneous within the product realized by
3DPrinting. According to method proposed by
(Vorndran et al., 2008) with the lowest strength
exhibits very large grains in the range upper than 20
µm with a small contact areas, the grain size has a
similar magnitude as for the initial powder.
The research is particularly interested by the
inkjet printing characterization and the
improvement of the texture quality. First of all, the
study will be replaced in the AM context and the
specific technology used. Secondly, the approach
results in choose the adapted specimens for the
visual observations and the pictures measure before
an image processing. The image processing is the
chosen principle to analyze the texture quality by
pixels scanning. Finally, study will focus on a text
letter to apply the method.
Some researchers studied the effect of binder
jetting in order to characterize the concentration of
binder which influences properties of sintered parts
by 3DP (Chumnanklang et al., 2007) and the effect
of layer thickness and printing orientation in the
specific applications in 3DP (Farzadi et al., 2014;
Vaezi and Chua, 2010). The studies show that
selection of a proper binder is essential in
manufacturing with good surface finish,
dimensional accuracy, and high resolution. Several
binders were investigated in terms of their physical
properties, printing performance, and binder-
powder bed interaction (Moon et al., 2002).
In the same way, researches try to exploit the
color capabilities of 3D Printing to enhance the
visual appearance of reproduced objects (Cignoni et
al., 2008). The color measurement is an issue
because the 3D printing has much more rough
surface than conventional ink-jet prints. Another
article shows that 3D printing is capable of printing
in “full” color with current systems similarly as in
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 conventional color ink-jet printing. The basis of
color reproduction and color measurements
methodology, as well as the color permanence or
color stability, are described and discussed by
(Stanic and Lozo, 2010) and their work further
explains the current possibilities of color 3D ink-jet
printing and defines the importance of color
monitoring and control, as well as the color
permanence issues, in 3D printing. A method
presents how to measure and characterize color
performance of 3D Printing process in using a
multi-spectral imaging system with determined
average systematic color measurement error to
predict the surface quality according the
manufacturing orientations (Eiríksson et al., 2015).
This method proposes a “3D LookUp Table”
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relating the input color values to the empirically
measured color values. This provides a simple way
to perform a color prediction given an input color
value. The color stability of samples studied
noticeably varied and depends on color, percentage
of ink coverage and finishing method (Maja Stanic
et al., 2012). Another method of improving color
quality in an object created by a powder fabrication
system that uses a fluid ejection process causing a
reaction between the first material and the second
material that renders the colorant insoluble and
reduces penetration of the colorant to keep the
colorant near a surface of the layer (Nielsen et al.,
2010). Some papers focus on redesigning a 3D
printing machine, using piezoelectric demand‐mode
technology head in order to improve the factors of
accuracy, surface finishing and color quality of
fabricated models (Rahmati et al., 2009a, 2009b).
None of these articles provides a solution to correct
the image alteration from 3D Printing by inkjet.
The texture distortion depends also on droplet
technology and the manufacturing scanning.
As the manufacturing aspects of the product are
attached to the design approach, many essential
parameters are added to design process.
Manufacturability’s analysis and guidelines
application to improve design solutions are strongly
related to a know-how linked to manufacturing
problems. However, they do offer no real model of
formal integration. This is done "mentally" on the
originally defined product data (often geometric
data) (Skander et al., 2007; Swift and Brown,
2003). Therefore, a method can be implemented in
upstream of design process by capitalizing data in
the knowledge management.
2.3 Specimens manufacturing
Design For Manufactruing (DFM) approach
(Zhao and Shah, 2002) is used through different
visual tests in order to take in account the
requirements data into the numerical analysis.
Many manufacturing characteristics have been
integrated to determine the printing behaviors, such
as the layers manufacturing, the materials or the
new 3D printing technics. The study presents an
alternative to original model from the image
processing, mainly the outlines optimization and
the Design For Manufacturing. DFM allows
analyzing of manufacturability and implementation
of guidelines (trade rules) to improve the design
solution (Swift and Brown, 2003). These guidelines
are strongly oriented by knowledge on
manufacturing issues and match which is called
knowledge bases. This work implements the
manufacturing knowledge to enhance the 3DP
product quality in acting on digital model.
The experimental process is based on one type
of specimen manufactured in several directions.
First of all, the approach produced samples from
the same textures and the study observes the
printing quality. Authors precisely wish to study the
edges of each printed element. Specimens have
been designed with predefined images properties:
- Size : 1181 x 591 pixels / 416,6 x 208,5 mm
- Resolution : 72 pixels/inch
- Thickness : 10 mm
There are many ways to manufacture the
rectangular specimens through the 3DP. This
approach orientates them parallel to xy plane, then
zx and finally zy. The 3D model is sized according
to the same parameters. The research specifies the
specimens’ orientation on each image (Fig2.).
Fig 2. Specimens’ presentation
The specific software is configured with a
downsample texture larger than 2048 pixels in
order not to affect the quality of the original image.
After manufacturing, the study gets three specimens
according to xy, zx, zy planes (Fig 3.) and two other
specimens with a 45° angle.
Page 3 sur 9

a b c fig 3) with a shift of the ink projection in the
Fig 3. Printed specimens (a. zx plane specimen, b. zy
plane specimen, c. xy plane specimen)
This approach requires add functions on the chosen
image to thereafter study other characteristics
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(minimum thickness of a line, colors quality…).
From the realization, the study observes significant
differences between parts which will be used for
future studies. The approach is based on a global
overview which will tend to other tests (Annex1.).
Tab 1. Specimens’ analysis: singularities
The singularities show a loss of printing quality
with the disappearance of several details. For
example, the study can observe the withdrawal of 1
pixel thick lines on the zy sample, or the appearance
of trail in zx plane due to manufacturing constraints.
These first empirical tests demonstrate that the
sample printed on the xy plane is of better quality
than the others concerning the texture contrast. The
research anteriority shows that the layer thickness
printed in x direction has more dimensional
accuracy and significantly close to CAD software
based designs with predefined pore size, porosity
and pore interconnectivity (Farzadi et al., 2014).
The manufacturing layers apply a slicing of texture
in z, and cut the texture by superposition. The
displacement of printing head scans the layer on y
axis to deposit the ink and the binder
perpendicularly to building platform. Consequently,
the texture is distorted on the zy plane (specimen b,
printing direction y. The xy plane is more accurate
for depositing the ink with an orthogonal printing of
a texture. Then, the approach gets different images
that could be superimposed on the exact size of the
original image to realize the following study.
In the following section, the approach will
precisely define the selected method and focus on
the outlines quality of a letter on the xy plane. The
following study begins with linear 3D surfaces in
order to realize a first evaluation of the texture
quality. This approach is simpler for mixed several
results.
2.4 Image processing
To study the outline of a letter on the printed
sample, the approach uses SciLab 5.5 (Enterprises
and others, 2012). Languages such as Matlab and
Scilab are quite efficient to allow any kind of image
and signal processing almost directly in their
respective numerical interface. Both allow the study
of advanced image processing and matrix
computation. It is also possible to create scripts and
build customs programs with a graphical user
interface in both software (Klein et al., 2008).
Scilab is used in this study through an inspection
approach of texture got by binder jetting of 3D
printer. The manufacturing inspection has an
importance to prevent the risk of delivering a lower
product quality (Malek et al., 2013) and can be
involved to image processing.
Dosing liquids in small quantities is present in
several applications as the binder jetting by 3D
printing. Currently, researchers study the “Drop On
Demand (DOD) printhead based on a piezo-element
bender actuator which can generate drops out of
wax or the assessment of surface quality on part
textured” according to (Antonio Armillotta, 2006;
Ottnad et al., 2012). Nevertheless, the surface
texture in 3DP inkjet has not been assessed by
measuring the contours quality of letters. The
research process is defined through an image
processing to explain the method (Fig 4.). First of
Page 4 sur 9
 all, the virtual design applies a texture upon a 3D a b c
model which will be printed. As explained before,
this 3D model is dimensioned according to the size
of the image to keep the same scale. Secondly,
specimen has been photographically measured to
analyze the texture printed upon the physical model
under the same conditions (a single photo, the same
brightness, orthogonal…). The image acquisition
procedure has used a high definition device (18
MPixels) perpendicularly to specimen with a tripod
and under a controlled light (brightness level = 618 Fig 5. Image processing: xy plane specimen (a. digital
Lumens). Eventually, the process optimizes the model, b. printed model, c. measure in image processing)
original model according to the results of image
processing and the process generates a new The manufacturing behaviors explain the offset
congruent model to print. The image processing and printing with the x axis movement and the droplets
the edges corrections are concretely described in deposited by the printing head. The approach needs
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the § 3. to refine this observation with outline analysis and

Fig 4. Research process on the 3D inkjet printing
Authors compare the original image with the
picture got by 3D Printing. Therefore, the approach
must begin by converting RGB images to gray
images to realize a matrix study of pixels
throughout a defined function G as shown in (1).
The processed image is a gray image with the same
data type as RGB image.
edge detection on the letter A. Moreover, it could
go further in comparing each specimen according to
the manufacturing direction, but authors wish to
study the other behaviors before cross-checking
information. However, a tint analysis on gray
images and a histogram study of white and black
rate (Fig 6.) shows of new results according to the
printing orientation and also to verify some
observations. Those results confirm the
observations submitted into section 2.3. The xy
plane appears with better textures and yz plane
integrates the worse black tint.

G = rgb2gray(imRGB) (1)

A basic operation of superposition shows us an

offset printing to x direction on the specimen from
xy plane (Fig 5.). The approach uses the
“imsubstract” function in SciLab 5.5 and SIVP
(Scilab Image and Video Processing Toolbox)
where an image can be subtracted to another image
or a constant according to calling sequence (as seen Fig 6. Tint analysis (gray shade / histograms) (Scilab
in (2)). 5.5)

imout = imsubtract(im1, im2) (2) 2.5 Synthesis

However, you have to download and install the
SIVP module in SciLab.
The proposed research process allows pictures
analysis thanks to Scilab software and a pixels
scanning. The analysis is based on the images
comparison between the original and the final
model. A first visual study has observed the first
samples to find an operation way. The review

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 observed several singularities and especially an
offset on xy plane of the ink-jet printing and its
influence on the contour of a letter. The DFM
approach is centered on the impact of inkjet
printing throughout the texture quality in 3D
Printing to capitalize the observations or measures
of data from the image processing in order to
enhance and modify the original model. Moreover,
the study hasn’t found an equivalent research to
improve the 3D inkjet printing from image
processing. This principle has to allow the model
adaptation in upstream of design to get a consistent
model. Authors associate those observations
depending on manufacturing constraints from trade
rules. In the next section, the article presents the
approach of the outline enhancement and the results
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of pixels to the right and left of model (Annex2.).
The algorithm scans the picture from left to right to
determine the gray level change and thus determine
a contour at the same threshold. Algorithm allows
detecting the edges of each side of the letter by
horizontally scanning the shades of gray in the
matrix to trace the last pixel and thus the outline.
You can find out the detection and the correction
process of contours in the figure 7. The
computation is fast on this type of specimens, but it
can be longer with complex texture and a set of
letters.
The results show a heterogeneous deviation
along the right edge of A with a varying deflection
from 2 to 6 pixels due to offset printing technology

obtained by 3DP. (Contour A1 – Fig 7). The next step uses the mirror
of contour deviation to modify the original A
3. Results (Digital A2 – Fig 7) to print a new A (Printed A2 –
Fig 7). The provided algorithms can restore the
An edge detection program supported by SciLab outline.
has been used to shape the contour by scanning the
model on the rows of the matrix in converting
images to gray images. A gray image is composed
mainly of shades of gray, varying from black to
white with weakest and strongest shades (Sonka et
al., 2014). The number on the line i and the column
j indicates the intensity of the associate pixel
(Kuninari et al., 2008). A gray-scale image is
simply one in which the only colors are shades of
gray. The reason why the approach differentiates
such images from any other sort of color images is
that less information is required for each pixel. One
of the strongest points of SciLab is its ability to deal
with different kind of pictures.
Fig 7. Contours detection and correction
This part begins by analyzing the edge of the The last operation comes to verify the result by
first printed A to get the first contour. Then the
detecting the final contour; it shows a printing
process transforms the original A with the observed optimization. You can look at the checking of new
offset to create a new A. In order to cut the offset,
contour A2 on the Figure 7. The right edge is
the process modifies the right edge of the original A
corrected by the process and the new printed A is
according to the negative of the observed distortion. almost equivalent to the original A. The results
Finally, the modified A is reprinted to validate the
show an enhancement of new fabricated A by 3D
approach by checking the new outline. To realize inkjet printing with a contour closest to the original
the edge detection on the grayscale image, you have
A.
to define a threshold, from which the scanning
detects the boundary (Fig 8.). In the gray scale the
pixel value ranges from 0 to 255 (0=black,
255=white). The threshold is defined to 150 to tend
towards a good detection. In this algorithm, the
variables i and j scan the matrix line by line to
detect the gray values according to the selected
threshold. The process measures the edge deviation

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Fig 8. Detection function of contour
The main objective is to predict the printing offset
for each outlines letter or other textures. The edges
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correction generate by the image processing is
automatable throughout this suggested method in
SciLab. So far, the study focused on a precise detail
of samples with the enhancement of the contours
printing by inkjet of letters. This assembly method
presents the involvement of DFM approach to
influence the original design and optimize the
model without changing the binder jetting
technology by integrating its manufacturing trade
rules. Obviously, one type of sample is not
sufficient for validity of global model and a larger
number of tests by cross checking is required to
reduce the standard deviation.
4. Conclusion and discussion
The application suggests a method to correct an
original texture to optimize its contours in the xy
plane of manufacturing thanks to image processing.
The 3D printing by binder jetting which uses an
inkjet shows several singularities according to the
manufacturing constraints about the texture
printing. The study observed an offset of outline
around the printed letters and the research worked
on the assumption that the manufacturing direction
of the printing head was the influential factor. The
printing orientation influences the texture quality
according to the above observations and a tint
analysis confirms the results.
As main result, the aim was to enhance the
printing quality and the contour accuracy. The
program illustrates that image processing finds the
edge deviation throughout the A letter from
scanning method. The results show a heterogeneous
deviation along the right edge of A with a varying
deflection from 2 to 6 pixels due to offset printing
technology. The assembly method and algorithms
developed are reusable to correct the image
contours in upstream in the design and printing
software according to DFM approach. The digital
letter is modified according to the DFM approach to
get a congruent letter with additive manufacturing
by inkjet. The printing checking presents results
close to the original design. Outcomes show that
each measure of outlines has allowed the digital
model modification to finally get a better quality of
final product.
More broadly, the research planned to integrate all
the 3DP knowledge capitalized throughout the
samples printed by binder jetting in order to
generate an optimized texture from digital model
that corresponds to a better definition in
manufacturing. The texture quality and its
variations are obviously different in a layered
process and according to the x, y and z directions.
The figure 6 still shows difficulty about the tint
quality of the printing according to the
manufacturing direction. Thus, the results around
one sample aren’t enough to implement data and a
larger number of tests by cross checking is required
to reduce a standard deviation. This research and its
algorithms propose an approach able to improve the
texture quality in binder jetting technology in all
manufacturing directions and the first results show
the possibilities. The method does not impact 3D
printing machine because it acts on the original
digital picture. Therefore, the problematic is to
combine different corrections as shown above to
get a reliable model close to the global desired
texture according to the DFM approach.
A better texture would be beneficial to get a
more realistic 3D part without blur sensation in
order to have a high quality of rendering product.
The reproduction of art work or the representations
of very realistic architectural products are
applications to consider. The new designed and
manufactured 3D printing machine also provides
the ability to construct more accurate models with
improved quality. According to this paper, an
algorithm could also correct texture defaults due to
effects of 3D printing orientation.
Eventually, authors propose to continue the
study to generate a global model which depends on
all the trade rules from binder jetting by 3D printing
to optimize the process.
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 Biographical notes: Julien Gardan is assistant
professor in EPF engineering school in Troyes
since 2013 and researcher in Additive
Manufacturing and System Engineering attached to
LASMIS (Laboratory of Mechanical systems and
concurrent engineering) of the University of
Technology of Troyes (UTT, France). Julien
received his PhD in 2011 from UTT (France). His
research spans the areas of rapid prototyping,
additive manufacturing, Computer Aided
Engineering and System Engineering.
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6. Annex

Annex1. Characterization of 3D inkjet printing and its

optimization

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Fig 1. 3D Printer manufacturing chamber

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Fig 2. Specimens’ presentation

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Fig 3. Printed specimens

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Tab 1. Specimens’ analysis: singularities

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Fig 4. Research process on the 3D inkjet printing

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Fig 5. Image processing: xy plan specimen

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Fig 6. Tint analysis (gray shade / histograms) (Scilab 5.5)

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Fig 7. Contours detection and correction

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Fig 8. Detection function of contour

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Annex1. Characterization of 3D inkjet printing and its optimizatio

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Annex2. Edge deviation function to left or to right

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3D Model Image

New image
Specific software
from 3D Printer

Manufacturing Printing of color Projet

orientation 3D model 460 Plus
Outline correction

Texture
prototype
surface

High definition Image Yes

distortion ?
Image processing
photography

No

Final product

Annex3. Flowchart of the technical procedure