Abstract:The binder jet 3D printing (BJ3DP) process is currently a research hotspot. Generally, the powder bed printing process requires spherical powders, which limits the preparation and fabrication of some high-entropy alloy (HEA) powders with significant melting point differences. This study mainly focuses on the BJ3DP-sintering behavior of non-spherical particles. The results show that the non-spherical AlTiCrNiCu low-density HEA powder with bcc structure was prepared via mechanical alloying, with a particle size distribution of 6.72–67.52 μm and an average particle size of 21.17 μm, which complies with the process requirements of BJ3DP. The results of orthogonal experiment indicate that under the condition of ensuring green part morphology integrity, the higher green density (approximately 44.4%) is achieved in BJ3DP with a binder saturation of 70%, a layer thickness of 120 μm, and a powder spreading speed of 5 mm/s. After sintering at 1190 ℃ for 4 h, the relative density of the sintered sample reaches 91.6%. The AlTiCrNiCu low-density HEA exhibits a multiphase structure consisting of B2 phase as matrix, along with bcc, fcc, and a small amount of L21 phase. The AlTiCrNiCu low-density HEA exhibits high compressive properties, with a yield strength and compressive strength of approximately 840 and 960 MPa, respectively.