Additive Manufacturing of Tailored Macroporous Ceramic Structures for High‐Temperature Applications

Sobhani, Sadaf; Allan, Shawn M.; Muhunthan, Priyanka; Boigné, Emeric; Ihme, Matthias

doi:10.1002/adem.202000158

Cited by 21 publications

(6 citation statements)

References 24 publications

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“…Such characteristic depends closely on the solid loading and sintering temperature [198]. Finally, this process presents outstanding surface quality and roughness (Ra) below 0.5 μm have been reported [4,166,188,199]. Research about ceramic VP has become widespread in recent years and over 30 research institutions published at least 10 papers indexed by the Web of Science in the last 5 years.…”

Section: Vat Photopolymerizationmentioning

confidence: 99%

A review on the ceramic additive manufacturing technologies and availability of equipment and materials

2022

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Ceramic additive manufacturing allows the fabrication of small series of complex parts without the high costs of molds usually associated with traditional ceramic processing. Although research into ceramic 3D printing by all technologies started back in the 90s, its industrial application is still quite restricted when compared to polymers and metals, which is related to the limited availability and costs of equipment and materials for such applications. This review examined the advantages and limitations of each process (binder jetting, direct ink writing, directed energy deposition, fused deposition, material jetting, selective laser sintering, selective laser melting, and vat photopolymerization), discussing their particularities. It also summarized the commercially available 3D printers and raw materials for ceramic processing, pointing out to trends and challenges of each technology.

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Section: Vat Photopolymerizationmentioning

confidence: 99%

A review on the ceramic additive manufacturing technologies and availability of equipment and materials

2022

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“…The focus of this research was to analyze the mechanical amplification behavior and, most especially, the influence of the interface between building blocks and the PZT-filled resin on the fracture behavior. The results show that the processing caused a gradient structure [22][23][24][25][26][27] and a textured surface [22,23,[28][29][30][31][32].…”

Section: Introductionmentioning

confidence: 98%

Improved Mechanical Amplification of Monolithic PZT and PZT Composite via Optimized Honeycomb Macrostructures

et al. 2022

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Honeycomb-based, modular composites with a relative density of 0.3948 and a slenderness ratio Lges/t of 6.48 were fabricated on PZT building blocks connected with a PZT-filled phenyl silicone resin. The macro- and micro-structure, phase composition, and the interface between the two materials were analyzed by SEM and image analysis techniques. The mechanical in-plane strain response was determined with uniaxial compression tests and the transversal piezoelectric strain response was determined by applying an electric field. These deformations were analyzed by a 2D digital image correlation analysis to calculate the mechanical strain amplification of monolithic and composite PZT lattice structures. Compared to bulk PZT, the piezoelectric strain amplification in the Y-direction |aypiezo| was higher by a factor of 69 for the composite and by a factor of 12 for the monolithic cellular PZT lattice, when it was assumed that the ratio of the deformation of the bulk material to bulk material was 1. The mechanical amplification of the composite lattices increased up to 73 and that of the cellular PZT lattices decreased to 12. Special focus was given to the fracture behavior and the interface of the PZT/PZT-filled phenyl silicone resin interface.

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“…In this context, porous ceramic FGCs gained recent interest as next generation biomaterials to overcome the mechanical weaknesses of homogeneous porous ceramics by combining the advantageous of dense and porous ceramics in a single material [7,[11][12][13][14]. Porous FGCs are characterized by a gradient in their density, which can be continuous (gradually [15][16][17][18]) or discontinuous (stepwise [7,[19][20][21][22]) and arranged in layers [21,22]) or as core-shell structures [7,15,19,20]), as schematically shown in Figure 1. The density gradient ρ i (x,y,z) induces location-dependent properties M i (x,y,z) along the spatial directions (x,y,z) and thus perspective biomedical applications that cannot be achieved by common homogeneous porous ceramics, for which ρ i and M i are constant in volume [23][24][25].…”

Section: Introductionmentioning

confidence: 99%

“…The density gradient ρ i (x,y,z) induces location-dependent properties M i (x,y,z) along the spatial directions (x,y,z) and thus perspective biomedical applications that cannot be achieved by common homogeneous porous ceramics, for which ρ i and M i are constant in volume [23][24][25]. Graded porosities were commonly achieved by modifying established fabrication techniques of homogeneous porous ceramics, including sacrificial templating [7,14,21,22,26], direct foaming [15,18,27], freeze casting [19,28], emulsion forming [29,30], replica technique [20,[31][32][33] and additive manufacturing (AM) [16,17,31,32]. Among the various mentioned processing routes, techniques utilizing computer-aided designing provide the highest potential to realize freely adjustable graded architectures with complex shapes [17,31], which are required for the fabrication of patient individual implants.…”

Section: Introductionmentioning

confidence: 99%

Porous Functional Graded Bioceramics with Integrated Interface Textures

et al. 2021

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Porous functional graded ceramics (porous FGCs) offer immense potential to overcome the low mechanical strengths of homogeneously porous bioceramics used as bone grafts. The tailored manipulation of the graded pore structure including the interfaces in these materials is of particular interest to locally control the microstructural and mechanical properties, as well as the biological response of the potential implant. In this work, porous FGCs with integrated interface textures were fabricated by a novel two-step transfer micro-molding technique using alumina and hydroxyapatite feedstocks with varied amounts of spherical pore formers (0–40 Vol%) to generate well-defined porosities. Defect-free interfaces could be realized for various porosity pairings, leading to porous FGCs with continuous and discontinuous transition of porosity. The microstructure of three different periodic interface patterns (planar, 2D-linear waves and 3D-Gaussian hills) was investigated by SEM and µCT and showed a shape accurate replication of the CAD-designed model in the ceramic sample. The Young’s modulus and flexural strength of bi-layered bending bars with 0 and 30 Vol% of pore formers were determined and compared to homogeneous porous alumina and hydroxyapaite containing 0–40 Vol% of pore formers. A significant reduction of the Young’s modulus was observed for the porous FGCs, attributed to damping effects at the interface. Flexural 4-point-testing revealed that the failure did not occur at the interface, but rather in the porous 30 Vol% layer, proving that the interface does not represent a source of weakness in the microstructure.

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Additive Manufacturing of Tailored Macroporous Ceramic Structures for High‐Temperature Applications

Cited by 21 publications

References 24 publications

A review on the ceramic additive manufacturing technologies and availability of equipment and materials

A review on the ceramic additive manufacturing technologies and availability of equipment and materials

Improved Mechanical Amplification of Monolithic PZT and PZT Composite via Optimized Honeycomb Macrostructures

Porous Functional Graded Bioceramics with Integrated Interface Textures

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