Additive Manufacturing of ceramic components by Digital Light Processing: A comparison between the “bottom-up” and the “top-down” approaches

Santoliquido, Oscar; Colombo, Paolo; Ortona, Alberto

doi:10.1016/j.jeurceramsoc.2019.01.044

Cited by 166 publications

(83 citation statements)

References 7 publications

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“…Stereolithography Stereolithography (SL) is considered as the most prominent and popular 3D printing technique and has been applied for the fabrication of polymer, ceramic, and glass parts (Eckel et al, 2016;Ngo et al, 2018;Santoliquido et al, 2019). A schematic of the SL process is shown in Figure 7A.…”

Section: Lithography-based 3d Printing Of Solid-state Electrolytesmentioning

confidence: 99%

“…The emergence of 3D printing technique offered a unique manufacturing method that has the feasibility to build parts with high complexity and fine features Santoliquido et al, 2019). Although using the 3D printing technique could be a promising alternative option in SSE manufacturing, the original purpose for the development of 3D printing was not targeted to produce batteries.…”

Section: Introductionmentioning

confidence: 99%

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Manufacturing Strategies for Solid Electrolyte in Batteries

Chen

Shi

et al. 2020

Front. Energy Res.

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Throughout the development of battery technologies in recent years, the solid-state electrolyte (SSE) has demonstrated outstanding advantages in tackling the safety shortcomings of traditional batteries while meeting high demands on electrochemical performances. The traditional manufacturing strategies can achieve the fabrication of batteries with simple forms (coin, cylindrical, and pouch), but encounter limitations in preparing complex-shaped or micro/nanoscaled batteries especially for inorganic solid electrolytes (ISEs). The advancement in novel manufacturing techniques like 3D printing has enabled the assembly of different solid electrolytes (polymeric, inorganic, and composites) in a more complex geometric configuration. However, there is a huge gap between the capabilities of the current 3D printing techniques and the requirements for battery production. In this review, we compare the traditional manufacturing to several novel 3D printing techniques, highlighting the potential of 3D printing in the SSE manufacturing. The latest SSE manufacturing progress in the group of direct-writing (DW) based or lithography-based printing technologies are summarized separately from the perspectives of feedstock selection, build envelope, printing resolution, and application (nano-scaled, flexible, and large-scale battery grids). Throughout the discussion, some challenges associated with manufacturing SSEs via 3D printing such as air/moisture sensitivity of samples, printing resolution, scale-up capability, and longterm sintering for ISEs have been put forward. This review aims to bridge the gap between 3D printing techniques and battery requirements by analyzing the existing limitation in SSE manufacturing and point out future needs.

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Section: Lithography-based 3d Printing Of Solid-state Electrolytesmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Manufacturing Strategies for Solid Electrolyte in Batteries

Chen

Shi

et al. 2020

Front. Energy Res.

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“…SLA allows for the fabrication of three-dimensional polymeric parts with UV radiation that induces the photopolymerization of a reactive monomer. The structures were manufactured using a 3D printer (GiziMate, Gizmo 3D Printers, Brisbane, Australia) by exploiting the top-down approach [34]. In this process, the STL model is sliced into two-dimensional cross-sections, allowing for their projection in sequence and building the part layer by layer.…”

Section: Manufacturingmentioning

confidence: 99%

Nature-Inspired, Ultra-Lightweight Structures with Gyroid Cores Produced by Additive Manufacturing and Reinforced by Unidirectional Carbon Fiber Ribs

Pelanconi

Ortona

2019

Materials

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This article reports on a nature-inspired, ultra-lightweight structure designed to optimize rigidity and density under bending loads. The structure’s main features were conceived by observing the scales of the butterflies’ wings. They are made of a triply periodic minimal surface geometry called gyroid and further reinforced on their outer regions with a series of ribs. In this work, the ribs were substituted with carbon fiber-reinforced bars that were connected to the main structure with an innovative concept. Stereolithography was used to print a plastic component in one piece that comprised the core and the connection system. Bending tests were performed on the structures along with a Finite Element Method optimization campaign to achieve the optimum performance in terms of stiffness and density. Results show that these architectures are among the most effective mechanical solutions in respect to their weight because of their particular arrangement of material in space.

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“…The DLP-stereolithography was used to prepare Al2O3 ceramic parts with good surface quality and a relative density of 93.2%, which demonstrated the effectiveness of DLPstereolithography [11]. Works by O. Santoliquido et al [17] and X. Shuai et al [18] have detailed the use of DLP-stereolithography for the fabrication of Al2O3 architectures with fine and complex lattice structures. However, it is worth noting that the presence of photosensitive resin in printed green parts and its removal during the debinding process can result in a large porosity in the debound parts [19], which can lengthen the pathways for substance migration at high temperatures and be an obstacle for the sintering densification [20,21].…”

Section: Introductionmentioning

confidence: 97%

Microstructure refinement - homogenization and flexural strength improvement of Al2O3 ceramics fabricated by DLP-stereolithography integrated with chemical precipitation coating process

Nie

Sheng

et al. 2020

Preprint

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In this study, the chemical precipitation coating (CP) process was creatively integrated with DLP-stereolithography based 3D printing for refining and homogenizing the microstructure of 3D printed Al2O3 ceramic. Based on this novel approach, Al2O3 powder was coated with a homogeneous layer of amorphous Y2O3; with the coated Al2O3 powder found to make the microstructure of 3D printed Al2O3 ceramic more uniform and refined, as compared with the conventional mechanical mixing (MM) of Al2O3 and Y2O3 powders. The grain size of Al2O3 in Sample CP is 64.44% and 51.43% lower than those in the monolithic Al2O3 ceramic (AL) and Sample MM, respectively. Sample CP has the highest flexural strength of 455.37±32.17 MPa, which is 14.85% and 25.45% higher than those of Samples MM and AL, respectively; also Sample CP has the highest Weibull modulus of 16.88 among the three kinds of samples. Moreover, the fine grained Sample CP has a close thermal conductivity to the coarse grained Sample MM because of the changes in morphology of Y3Al5O12 phase from semi-connected (Sample MM) to isolated (Sample CP). Finally, specially designed fin-type Al2O3 ceramic heat sinks were successfully fabricated via the novel integrated process, which has been proven to be an effective method for fabricating complex-shaped Al2O3 ceramic components with enhanced flexural strength and reliability.

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Additive Manufacturing of ceramic components by Digital Light Processing: A comparison between the “bottom-up” and the “top-down” approaches

Cited by 166 publications

References 7 publications

Manufacturing Strategies for Solid Electrolyte in Batteries

Manufacturing Strategies for Solid Electrolyte in Batteries

Nature-Inspired, Ultra-Lightweight Structures with Gyroid Cores Produced by Additive Manufacturing and Reinforced by Unidirectional Carbon Fiber Ribs

Microstructure refinement - homogenization and flexural strength improvement of Al2O3 ceramics fabricated by DLP-stereolithography integrated with chemical precipitation coating process

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