Purpose This study aims to fabricate complex ceramic tetrahedron structures, which are challenging to produce by more conventional methods such as injection molding. To achieve this aim, thermoplastic-ceramic composite filaments were developed and printed with unmodified, consumer-grade, fused deposition modelling (FDM) printers instead. Design/methodology/approach Al2O3 ceramic powder was mixed with ethylene vinyl acetate polymer as a binder (50 Vol.- per cent) to form a filament with a constant diameter of 1.75 mm. After the printing and thermal treatment stages, the shrinkage and mechanical properties of cuboid and tetrahedron structures were investigated. Findings The shrinkage of the parts was found to be anisotropic, depending on the orientation of the printing pattern, with an increase of 2.4 per cent in the (vertical) printing direction compared to the (horizontal) printing layer direction. The alignment of the ceramic particle orientations introduced by FDM printing was identified as a potential cause of the anisotropy. This study further demonstrates that using a powder bed during the thermal debinding process yields sintered structures that can withstand twice the compressive force. Originality/value Ceramic FDM had previously been used primarily for simple scaffold structures. In this study, the applicability of ceramic FDM was extended from simple scaffolds to more complex geometries such as hollow tetrahedra. The structures produced in this study contain dense parts printed from multiple contiguous layers, as compared to the open structures usually found in scaffolds. The mechanical properties of the complex ceramic parts made by using this FDM technique were also subjected to investigation.

Recent experimental results have shown that binary granular materials fluidized by combined vibration and gas flow exhibit Rayleigh-Taylor-like instabilities that manifest themselves in rising plumes, rising bubbles, and the sinking and splitting of granular droplets. This work explores the physics behind the splitting of a granular droplet that is composed of smaller and denser particles in a bed of larger and lighter particles. During its sinking motion, a granular droplet undergoes a series of binary splits resembling the fragmentation of a liquid droplet falling in a miscible fluid. However, different physical mechanisms cause a granular droplet to split. By applying particle image velocimetry and numerical simulations, we demonstrate that the droplet of high-density particles causes the formation of an immobilized zone underneath the droplet. This zone obstructs the downwards motion of the droplet and causes the droplet to spread and ultimately to split. The resulting fragments sink at inclined trajectories around the immobilized zone until another splitting event is initiated. The occurrence of consecutive splitting events is explained by the reformation of an immobilized zone underneath the droplet fragments. Our investigations identified three requirements for a granular droplet to split: (1) frictional interparticle contacts, (2) a higher density of the particles composing the granular droplet compared to the bulk particles, and (3) a minimal granular droplet diameter.

The effect of internals on the fluidization dynamics in three-dimensional (3D) cylindrical fluidized beds was studied using real-time magnetic resonance imaging. Instantaneous snapshots of particle velocity and particle position were acquired for gas velocities U below and above the minimum fluidization velocity Umf. Below Umf, we found local fluidization and gas bubbling in areas adjacent † This is an accepted preprint of the article published by the authors. The published version can be found on the webpage of Chemical Engineering Science at

An external load on a particle packing is distributed internally through a heterogeneous network of particle contacts. This contact force distribution determines the stability of the particle packing and the resulting structure. Here, we investigate the homogeneity of the contact force distribution in packings of highly nonconvex particles both in two-dimensional (2D) and three-dimensional (3D) packings. A recently developed discrete element method is used to model packings of nonconvex particles of varying sphericity. Our results establish that in 3D packings the distribution of the contact forces in the normal direction becomes increasingly heterogeneous with decreasing particle sphericity. However, in 2D packings the contact force distribution is independent of particle sphericity, indicating that results obtained in 2D packings cannot be extrapolated readily to 3D packings. Radial distribution functions show that the crystallinity in 3D packings decreases with decreasing particle sphericity. We link the decreasing homogeneity of the contact force distributions to the decreasing crystallinity of 3D packings. These findings are complementary to the previously observed link between the heterogeneity of the contact force distribution and a decreasing packing crystallinity due to an increasing polydispersity of spherical particles.