Fabricating ceramic components with water dissolvable support structures by the Ceramic On-Demand Extrusion process

Li, Wenbin; Ghazanfari, Amir; McMillen, Devin; Leu, Ming-Chuan; Hilmas, Greg; Watts, Jeremy Lee

doi:10.1016/j.cirp.2017.04.129

Cited by 32 publications

(18 citation statements)

References 9 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…In case of MEX, the focus was mainly set on alumina, Materials 2021, 14, 5467 2 of 15 partially extending the application range to microsystems technology [19][20][21][22][23][24][25]. With respect to ceramic applications, which need enhanced mechanical properties, zirconia components made via MEX should be very promising, but little research can be found in the literature [26][27][28][29]. In 2021, the fabrication of zirconia parts applying MEX methods with an ethylene vinyl acetate containing binder was published [30,31].…”

Section: Introductionmentioning

confidence: 99%

Printing of Zirconia Parts via Fused Filament Fabrication

et al. 2021

View full text Add to dashboard Cite

In this work, a process chain for the fabrication of dense zirconia parts will be presented covering the individual steps feedstock compounding, 3D printing via Fused Filament Fabrication (FFF) and thermal postprocessing including debinding and sintering. A special focus was set on the comprehensive rheological characterization of the feedstock systems applying high-pressure capillary and oscillation rheometry. The latter allowed the representation of the flow situation especially in the nozzle of the print head with the occurring low-shear stress. Oscillation rheometry enabled the clarification of the surfactant’s concentration, here stearic acid, or more general, the feedstocks composition influence on the resulting feedstock flow behavior. Finally, dense ceramic parts (best values around 99 % of theory) were realized with structural details smaller than 100 µm.

show abstract

Section: Introductionmentioning

confidence: 99%

Printing of Zirconia Parts via Fused Filament Fabrication

et al. 2021

View full text Add to dashboard Cite

show abstract

“…Scheithauer et al [ 32 ] put forward the thermoplastic 3D-printing process with a combination of FDM and robocasting, which utilized phase changing techniques to maintain the extrudate shape. In addition to the above mentioned single-extrudate retention methods, the approaches of using water dissolvable materials [ 33 ] or easily removed materials as support structures [ 34 ] also have been explored for fabricating more complex and precise structures.…”

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

View full text Add to dashboard Cite

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.

show abstract

“…and cannot be fabricated without the use of support,an inorganic sacrificial material(CaCO 3 )is used to build a support structure. The sacrificial material decomposes during sintering and then dissolves in water or acid afterwards [34].…”

Section: Process Overviewmentioning

confidence: 99%

A novel freeform extrusion fabrication process for producing solid ceramic components with uniform layered radiation drying

Ghazanfari

Leu

et al. 2017

Additive Manufacturing

Self Cite

View full text Add to dashboard Cite

An extrusion-based additive manufacturing process, called the Ceramic On-Demand Extrusion (CODE) process, for producing three-dimensional ceramic components with near theoretical densityis introduced in this paper.In this process, an aqueous paste of ceramic particles with a very low binder content (<1vol%) is extruded through a moving nozzle at room temperature. After a layer is deposited, it is surrounded by oil (to a level just below the top surface of most recent layer) to preclude non-uniform evaporation from the sides. Infrared radiation is then used to partially, and uniformly, dry the just-deposited layer so that the yield stress of the paste increases and the part maintains its shape. The same procedure is repeated for every layer until part fabrication is completed. Several sample parts for various applications were produced using this process and their properties were obtained. The results indicate that the proposed method enables fabrication of large, dense ceramic parts with complex geometries.

show abstract

Fabricating ceramic components with water dissolvable support structures by the Ceramic On-Demand Extrusion process

Cited by 32 publications

References 9 publications

Printing of Zirconia Parts via Fused Filament Fabrication

Printing of Zirconia Parts via Fused Filament Fabrication

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

A novel freeform extrusion fabrication process for producing solid ceramic components with uniform layered radiation drying

Contact Info

Product

Resources

About