Abstract:The binder jetting 3D printing (BJ3DP) process is currently a research hotspot. Generally, the powder bed printing process requires spherical powders, which limits the preparation and printing of some HEA powders with large melting point differences. This study mainly focuses on the BJ3DP printing-sintering behavior of non-spherical particles. The results showed that the near-spherical AlTiCrNiCu low-density HEA powder with BCC structure was prepared by mechanical alloying, with a particle size ranged from 6.72 to 67.52 μm and an average particle size of 21.17 μm, which met the requirements of the BJ3DP printing process. The results of the orthogonal experiment indicate that when the binder saturation is 60%, the layer thickness is 120 μm, and the powder feeding speed is 15 pps, the green density of BJ3DP printing is the highest (about 44.7%). After sintering at 1190℃ for 4 hours, the density of the green body reaches 91.6%. The AlTiCrNiCu low-density HEA has a multiphase structure, with the B2 phase as the matrix, including BCC, FCC, and a small amount of L21 phase. The AlTiCrNiCu low-density HEA has high compressive properties, with a yield strength and compressive strength of approximately 840 MPa and 960 MPa, respectively. The research results provide ideas and reference for the BJ3DP printing and sintering of non-spherical metal powders, further expanding the application scope of metal powder BJ3DP printing and forming.