A trial to convert a polymer FDM 3D printer to handle clay materials

Abstract

The research aims to show the ability to convert the Fused Deposition Modeling 3D printer to be compatible with the clay mixture after modifying the structure, setting up Cura software, and changing the print head technology. This solution provides research teams and scientists with opportunities in several ways (manufacture patch antenna substrate, dielectric automobile sensors, and ceramic dielectric aerospace technology). Additive manufacturing allows the production of many intricate shapes with ceramics, which is difficult with a traditional method. This paper used WASP ceramic slurry as raw material for Liquid Deposition Modeling (LDM) of various samples using the Archimedes screw and air pressure dispensing technique (a two-step process). LDM is a low-cost and straightforward technology appropriate for the clay prototype scale. Different clay-built shapes have been produced with water-to-clay ratios ranging from 0.57 to 0.69. The effect of the nozzle size in printing experiment tests is demonstrated. The experiment tested the print head (extruder) mechanism, the properties of the materials suitable for the putty, and how the wet slurry material is extruded from the nozzle. The optimum air pressure and slicing configuration for efficient printing are provided. Samples were stress-tested after they were dried for 24 h at average laboratory temperature and then exposed to 1000$$^\circ $$ ∘ for 1 h.