In the past decades, many binder-based powder metallurgy (PM) production routes have been developed. Among these technologies, the additive manufacturing (AM) technology binder jetting is ideally suited to produce individual components, as it offers the possibility for die-free shaping of geometrically highly complex components. Binder jetting is composed of two main processing steps: 1) binder-based 3D printing to produce green bodies with high porosity; 2) densification by sintering. As the volume change during the whole production chain can be from several percent up to 50%, there are still many challenges in conducting net-shape production of complex shaped components.

To assure the production of net-shape components with desired microstructure at the same time reduce the costs, a numerical toolbox was developed to model and simulate each manufacturing step on the entire process chain. Using discrete element simulation of the powder spreading process, the density distribution on the powder bed was determined numerically in 3D during the binder-based 3D-printing process. After evaluation of the results, the simulated density distribution was obtained and transferred to a finite element (FE) simulation model, so that a sinter simulation could be carried out. With the consideration of the influences of the density distribution on the green body, the gravity, as well as the friction between the sintering substrate and the sintering body, a precise prediction of the sintering shrinkage and the final geometry could be realised . In addition, with the help of an inverse optimisation, the geometry of the green parts could be optimised iteratively, with which the net-shape component with the desired geometry could be manufactured despite sintering distortion. Furthermore, an FE simulation could also be added to predict the phase fraction and the evolution of residual stresses during the heat treatment of the sintered components made of steel.