The biggest hurdle in the transition from Metal Binder Jetting pilot projects to true mass production rarely lies in the printing itself, but rather in sintering: Only those who have mastered consistently reproducible high-temperature sintering processes can reliably turn printed green parts into dimensionally accurate production parts. DSB Technologies, a U.S. powder metallurgy specialist based in Janesville, Wisconsin, brings more than four decades of experience to the table—and demonstrates how this expertise can be specifically applied to Metal Binder Jetting.

From Press Sintering to Binder Jetting: A Logical Extension

DSB Technologies has been developing and manufacturing functional powder metal components for the automotive industry for decades and is increasingly expanding this portfolio to include sporting goods, medical technology, and industrial applications. The company has traditionally utilized press sintering (PM) and metal injection molding (MIM) technologies and, according to its own figures, processes over 3.5 million kilograms of metal powder per year, including more than three million kilograms of stainless steel. By its own estimation, it has the largest high-temperature sintering capacity in North America. Paul Hauck, Chief Operating Officer at DSB Technologies, describes the rationale behind the expansion to include Desktop Metal Shop System and X-Series technology as follows: “Our high-temperature sintering capacity makes this business well-suited for technologies such as PM press and sinter, metal injection molding, and metal binder jetting.”

The advantage for DSB is clear: Anyone who can already reliably sinter MIM components automatically possesses the critical process knowledge required for metal binder jetting. Hauck adds: “Converting a printed part into a final sintered part requires high-temperature sintering of fine metal powders. This is exactly what the MIM industry understands—they’re very good at it. So, if you’re successful at making MIM parts, you have a high likelihood of being successful at making binder-jet parts.”

Three machines, a step-by-step path to series production

Instead of investing directly in a high-volume production system, DSB Technologies built up its binder jetting capacity step by step: In 2021, the compact InnoventX was first installed to test material development and initial sintering parameters on a small scale. This was followed in 2022 by the mid-sized X25Pro for application development and initial bridge production, and finally, in 2023, by the X160Pro with a build volume of 800 x 500 x 400 millimeters for full-scale production volumes. Senior Additive Manufacturing Engineer Neil Belanus describes the benefits of this phased approach: “Having all three X-Series machines is helpful for scalability. We can conduct material development, create small-scale prototypes, and carry out application development, as well as serial production of large parts—all within the same binder jetting platform.”

What this actually makes possible

The figures reported by DSB Technologies from real-world applications are impressive: According to the company, the dimensional stability of the binder jetting process after sintering is around ±1 percent—precise enough to significantly reduce the need for additional post-processing. A real-world example: a 24-pound (about 11-kilogram) stainless steel component that was successfully printed on the X160Pro—for Hauck, proof of entirely new application possibilities: “It’s a massive application, and we’ve already had a successful print run of it, and we’re going at it again. That’s exciting stuff; that could be a whole new world of metal part fabrication that we just haven’t been able to achieve with traditional MIM.” When it comes to development time, Hauck also provides concrete calculations of how much time the digital, tool-free process saves compared to conventional mold manufacturing: “You’re cutting as few as eight weeks—and maybe as many as 16 or 20 weeks—off that process.”

Belanus elaborates on the geometric freedom that metal binder jetting offers compared to MIM or traditional molding: “With metal binder jetting, we can produce parts without being constrained by common conventional design limitations. We’re seeing undercuts, internal cavities, and lattices—unique lightweighting features that were previously impossible. We can incorporate threads, spirals, and many other features that would be very difficult to achieve with conventional technologies.”

What this means for companies looking to invest themselves

The case of DSB Technologies makes it clear that the transition to metal binder jetting is all the easier the more existing sintering expertise is already in-house—and that a phased investment across multiple machine sizes can be more economically justified than a single large-scale investment. For companies looking to purchase their own binder jetting printer, DSB Technologies thus provides a practical argument: First, test materials and parameters on a small scale; then move toward application readiness using a mid-range development machine; and only then invest in the actual production machine—backed by the company’s own existing sintering infrastructure.

Take the Next Step Now

Would you like to find out whether additive manufacturing or 3D scanning is also worthwhile for your components and processes? The AM Pioneers team offers non-binding advice on technology, materials, and cost-effectiveness—based on real-world project experience with the partner technologies presented here.

Contact AM Pioneers for a personalized consultation regarding your specific application.

Case Study

Click here for the case study: https://www.desktopmetal.com/uploads/DM_CST_DSBTechnologies_230927.pdf