3D extrusion printing of magnesium aluminate spinel ceramic parts using thermally induced gelation of methyl cellulose

Biswas, Papiya; Mamatha, Sirisala; Naskar, Subhendu; Rao, Yadunandana N.; Johnson, Roy; Padmanabham, G.

doi:10.1016/j.jallcom.2018.08.152

Cited by 33 publications

(16 citation statements)

References 33 publications

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“…[ 106 ] Moreover, the printability of materials can be improved by reducing the solid–liquid ratio and mixing ceramic particles with organic polymer materials to reduce viscosity. [ 107 ] To obtain a 3D printing structure with high shape fidelity, the setting speed of the slurry is usually increased or the ceramic powders are mixed with organic materials with better gelling performance. Richard et al.…”

Section: Materials Used In Bone Reconstruction By Ammentioning

confidence: 99%

Recent Developments of Biomaterials for Additive Manufacturing of Bone Scaffolds

Zhang

et al. 2020

Adv Healthcare Materials

102

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Recent years have witnessed surging demand for bone repair/regeneration implants due to the increasing number of bone defects caused by trauma, cancer, infection, and arthritis worldwide. In addition to bone autografts and allografts, biomaterial substitutes have been widely used in clinical practice. Personalized implants with precise and personalized control of shape, porosity, composition, surface chemistry, and mechanical properties will greatly facilitate the regeneration of bone tissue and satiate the clinical needs. Additive manufacturing (AM) techniques, also known as 3D printing, are drawing fast growing attention in the fabrication of implants or scaffolding materials due to their capability of manufacturing complex and irregularly shaped scaffolds in repairing bone defects in clinical practice. This review aims to provide a comprehensive overview of recent progress in the development of materials and techniques used in the additive manufacturing of bone scaffolds. In addition, clinical application, pre-clinical trials and future prospects of AM based bone implants are also summarized and discussed.

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Section: Materials Used In Bone Reconstruction By Ammentioning

confidence: 99%

Recent Developments of Biomaterials for Additive Manufacturing of Bone Scaffolds

Zhang

et al. 2020

Adv Healthcare Materials

102

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“…As shown in Figure 14 , one multi-letter array (ncut) part was successfully printed with the online hot air flow drying. Obviously, in this context, the presented in situ hot air flow drying method has an advantage over the uniform layered radiation drying method [ 30 ]. This is because the latter is radiation drying in the same layer, which would cause nonuniform moisture gradients of different structural islands.…”

Section: Extrusion-based 3d-printing Methods With In Situ Hot Air Fmentioning

confidence: 99%

“…During the Ceramic On-Demand Extrusion (CODE) process, the pastes were extruded at room temperature and each layer was solidified via partial drying using an infrared lamp, with a liquid oil surrounding the part. Biswas et al [ 30 ] presented the shape-retention concept of thermally induced gelation of methyl cellulose; that is to say, the parts were simultaneously exposed to hot air during printing, causing immediate gelation of methyl cellulose undertaking retention of shapes. Ren et al [ 31 ] claimed that they provided a 3D gel-printing (3DGP) process with the bridge between the low cost of the Direct Inkjet Printing (DIP) process and the fast solidification of gelation.…”

Section: Theoretical Complexity and Enabling Schemes Of Extrusion-mentioning

confidence: 99%

Extrusion-Based 3D Printing of Ceramic Pastes: Mathematical Modeling and In Situ Shaping Retention Approach

Mikołajczyk

Pimenov

et al. 2021

Materials

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Extrusion-based three-dimensional (3D) printing methods are preferred and emerging approaches for freely digital fabrication of ceramics due to ease of use, low investment, high utilization of materials, and good adaptability to multi-materials. However, systematic knowledge still lacks an explanation for what is their 3D printability. Moreover, some uncontrollable factors including extrudate shape retention and nonuniform drying inevitably limit their industrial applications. The purpose of this research was to present a new shaping retention method based on mathematical synthesis modeling for extrusion-based 3D-printing of ceramic pastes. Firstly, the steady-state equilibrium equation of the extrusion process was derived to provide clearer theoretical indications than purely experimental methods. Furthermore, a mathematical description framework was synthesized to better understand the extrusion-based 3D-printing of ceramic pastes from several realms: pastes rheology, extrudability, shape-holdability, and drying kinetics. Secondly, for eliminating shaping drawbacks (e.g., deformation and cracks) originating from non-digital control factors, we put forward a digital shape-retention technology inspired by the generalized drying kinetics of porous materials, which was different from existing retention solutions, e.g., freezing retention, thermally induced gelation, and using removable support structures. In addition, we developed an in situ hot air flow drying device easily attached to the nozzle of existing 3D printers. Confirmatory 3D-printing experiments of thin-walled cone-shape benchmark parts and the fire arrowhead-like object clearly demonstrated that the presented shape-retention method not only upgraded layer-by-layer forming capability but also enabled digital control of extrudate solidification. In addition, many more experimental results statistically showed that both fully solid parts and purely thin-wall parts had higher dimensional accuracy and better surface quality than the offline drying method. The 3D printed ceramic products with complex profiled surfaces conceivably demonstrated that our improved extrusion-based 3D-printing process of ceramic pastes has game-changing potentials beyond the traditional craftsmanship capacity.

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“…3D printing of the honeycombs was carried out with simultaneous exposure to the MC gelation temperature of 45°C-60°C as described elsewhere. 22 The honeycombs with handleable strength was subjected to microwave for the uniform removal of water and sintered at 1390°C in an air sintering furnace (Deltech) at a ramp rate of 100°C/hr with a soaking period of 1 hour to ensure the simultaneous formation of cordierite phase and densification. These heating conditions were optimized based on the TG-DTA experiments at our laboratory.…”

Section: Methodsmentioning

confidence: 99%

3D printing of cordierite honeycomb structures and evaluation of compressive strength under quasi‐static condition

Mamatha

Biswas

Das

et al. 2019

Int J Applied Ceramic Tech

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Ceramic honeycombs exhibit unique mechanical properties based on engineered formulations and geometry of cells. Extrusion of formable paste through a complex honeycomb die is the commonly practiced technique for the manufacturing of honeycombs globally. Extrusion die fabrication is a complex process which necessitates sophisticated infrastructure facilities that provide high geometrical accuracy and finish to produce defect free honeycombs. Furthermore, every configuration of honeycomb requires a specific tool. Additive manufacturing (AM)/ 3D printing is a rapid prototyping technique which offers flexibility in fabrication of honeycombs with desired geometries from a virtual model directly. Further, this does not require complicated dies. In this study, viscoplastic printable cordierite raw mix paste with a shear rate exponent of 0.87 was printed into honeycombs with hexagonal, square, and triangular cells using a ram type 3D printer. The printed honeycomb samples are found to possess good integrity and near net shape after drying. Sintered 3D‐printed honeycomb samples of all configurations have exhibited cordierite as a major phase along with minor phases of magnesium aluminate (MgAl2O4) spinel, clinoenstatite (MgSiO3), and corundum (Al2O3) with sintered density of 2.41‐2.48 g/cc. The samples are also subjected to compression testing under quasi‐static condition. The study demonstrates 3D printing as a viable and flexible technique for rapid prototyping of honeycombs with desired configurations and engineered properties.

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3D extrusion printing of magnesium aluminate spinel ceramic parts using thermally induced gelation of methyl cellulose

Cited by 33 publications

References 33 publications

Recent Developments of Biomaterials for Additive Manufacturing of Bone Scaffolds

Recent Developments of Biomaterials for Additive Manufacturing of Bone Scaffolds

Extrusion-Based 3D Printing of Ceramic Pastes: Mathematical Modeling and In Situ Shaping Retention Approach

3D printing of cordierite honeycomb structures and evaluation of compressive strength under quasi‐static condition

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