Binder jetting relies on the infiltration of binder droplets into a porous powder bed, where the spatial arrangement of droplets critically influences feature formation and structural integrity. In particular, the role of droplet spacing in regulating infiltration behavior remains insufficiently understood. In this study, droplet infiltration is investigated using a reconstructed three-dimensional powder bed combined with a Volume of Fluid (VOF) model. Both single- and dual-droplet configurations are examined to isolate the effect of droplet spacing on spreading, merging, and capillary-driven penetration. The results show that droplet spacing governs the redistribution of liquid flow between lateral spreading and vertical infiltration. Three distinct regimes are identified as spacing decreases: independent infiltration at large spacing, cooperative merging at intermediate spacing, and over-penetration at small spacing. These regimes reflect a transition from isolated droplet behavior to strongly coupled infiltration within the pore network. An optimal spacing of approximately 150 μm is found to balance spreading and penetration, enabling continuous deposition with controlled infiltration depth. Experimental measurements show good agreement with numerical predictions, with an average deviation of 8.66%. The present study clarifies the mechanism by which droplet spacing controls infiltration behavior and provides practical guidance for parameter selection in binder jetting processes.
Wang et al. (Tue,) studied this question.