Extrusion-based additive manufacturing of yttria-partially-stabilized zirconia ceramics

Yu, Tianyu; Zhang, Ziyang; Liu, Qingyang; Kuliiev, Ruslan; Orlovskaya, Nina; Wu, Dazhong

doi:10.1016/j.ceramint.2019.10.245

Cited by 77 publications

(26 citation statements)

References 43 publications

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“…The gaps between roads are a direct consequence of the building strategy not only of FFF [ 8 , 14 , 31 ] but also of other MEX processes such as piston-based [ 33 , 34 ] or screw-based [ 31 , 35 ] systems. These gaps can appear as interroad defects, which are elongated voids in between the extruded roads and parallel to them, or as subperimeter voids, which are produced by the change of direction of the infill when it reaches the perimeter [ 8 , 14 ].…”

Section: Discussionmentioning

confidence: 99%

“…In FFF and the other MEX techniques [ 8 , 14 , 31 , 32 , 33 , 34 , 35 , 36 ], the generation of the shape by the extrusion of material strands, known as roads, can result in defects in the gaps between the strands or weak areas if the bonding between the strands is not sufficient [ 8 ]. In early investigations, different solutions were proposed to reduce these defects [ 8 , 10 , 37 ].…”

Section: Introductionmentioning

confidence: 99%

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Influence of the Infill Orientation on the Properties of Zirconia Parts Produced by Fused Filament Fabrication

et al. 2020

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The fused filament fabrication (FFF) of ceramics enables the additive manufacturing of components with complex geometries for many applications like tooling or prototyping. Nevertheless, due to the many factors involved in the process, it is difficult to separate the effect of the different parameters on the final properties of the FFF parts, which hinders the expansion of the technology. In this paper, the effect of the fill pattern used during FFF on the defects and the mechanical properties of zirconia components is evaluated. The zirconia-filled filaments were produced from scratch, characterized by different methods and used in the FFF of bending bars with infill orientations of 0°, ±45° and 90° with respect to the longest dimension of the specimens. Three-point bending tests were conducted on the specimens with the side in contact with the build platform under tensile loads. Next, the defects were identified with cuts in different sections. During the shaping by FFF, pores appeared inside the extruded roads due to binder degradation and or moisture evaporation. The changes in the fill pattern resulted in different types of porosity and defects in the first layer, with the latter leading to earlier fracture of the components. Due to these variations, the specimens with the 0° infill orientation had the lowest porosity and the highest bending strength, followed by the specimens with ±45° infill orientation and finally by those with 90° infill orientation.

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Section: Discussionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Influence of the Infill Orientation on the Properties of Zirconia Parts Produced by Fused Filament Fabrication

et al. 2020

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“…The same authors noted that the surface finish is an important source of cracks that can lead to lower mechanical strength. Yu et al [34] observed the shape of the stacked layers in the lateral walls of yttria-stabilized zirconia specimens, while Ra values higher than 30 µm were reported for yttria-stabilized zirconia with CeO 2 with the syringe extrusion process [35].…”

Section: Introductionmentioning

confidence: 99%

Effect of Printing Parameters on Dimensional Error and Surface Roughness Obtained in Direct Ink Writing (DIW) Processes

2020

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Prostheses made from ceramic materials have the advantages of producing little debris and having good durability, compared with those made from metal and plastic. For example, hip prostheses require a porous external area that allows their fixation by means of osseointegration and a solid internal area that will be in contact with the femoral head. The manufacturing of complex ceramic shapes, by means of machining processes, for example, is complicated and can lead to breakage of the parts because of their fragility. The direct ink writing (DIW) process allows the printing of ceramic pastes into complex shapes that achieve their final strength after a heat treatment operation. This paper studies both the dimensional error and surface finish of porous zirconia prismatic parts prior to sintering. The variables considered are infill, layer height, printing speed, extrusion multiplier and bed temperature. The responses are the dimensional error of the lateral walls of the samples and an areal roughness parameter, the arithmetical mean height, Sa. Mathematical models are found for each response, and multiobjective optimization is carried out by means of the desirability function. The dimensional error depends mainly on the interaction between layer height and infill, while the roughness on the interaction between infill and printing speed. Thus, infill is an important factor for both responses. In the future, the behavior of compact printed parts will be addressed.

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“…In the last twenty years, material extrusion additive manufacturing (MEAM) has grown from a prototyping technology to one that produces intricate structures such as tissue engineering scaffolds [1][2][3], electronic components [4][5][6] and spatially designed fibre-reinforced components [7,8]. MEAM also has the ability to use materials that are difficult to process with other manufacturing technologies such as cell-laden hydrogels [3,9,10] and ceramics [11][12][13]. These materials and applications are generally associated with a shift in the use of MEAM technology towards higher value applications, where fidelity and defects are critical, as opposed to prototyping.…”

Section: Introductionmentioning

confidence: 99%

FullControl GCode Designer: Open-source software for unconstrained design in additive manufacturing

Gleadall

2021

Additive Manufacturing

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A new concept is presented for the design of additive manufacturing procedures, which is implemented in open-source software called FullControl GCode Designer. In this new design approach, the user defines every segment of the print-path along with all printing parameters, which may be related to geometric and non-geometric factors, at all points along the print-path. Machine control code (GCode) is directly generated by the software, without the need for any programming skills and without using computer-aided design (CAD), STL-files or slicing software. Excel is used as the front end for the software, which is written in Visual Basic. Case studies are used to demonstrate the broad range of structures that can be designed using the software, Conformal lattice cells Conformal lattice cells Designed terminal lattice cells Directly design GCode (machine code) • No CAD • No STL files • No slicer software Mathematically define print-paths Systematically control all printing parameters Produce previously inconceivable geometric structures Achieve unparalleled printing quality with precise control of the process Draw strings < 1/10th nozzle diameter

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Extrusion-based additive manufacturing of yttria-partially-stabilized zirconia ceramics

Cited by 77 publications

References 43 publications

Influence of the Infill Orientation on the Properties of Zirconia Parts Produced by Fused Filament Fabrication

Influence of the Infill Orientation on the Properties of Zirconia Parts Produced by Fused Filament Fabrication

Effect of Printing Parameters on Dimensional Error and Surface Roughness Obtained in Direct Ink Writing (DIW) Processes

FullControl GCode Designer: Open-source software for unconstrained design in additive manufacturing

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