Influence of formulation parameters on the freeform extrusion process of ceramic pastes and resulting product properties

Finke, Benedikt; Hesselbach, Jutta; Schütt, Anna; Tidau, Marius; Hampel, Benedikt; Schilling, Meinhard; Kwade, Arno; Schilde, Carsten

doi:10.1016/j.addma.2019.101005

Cited by 10 publications

(9 citation statements)

References 22 publications

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“…For building a completely programmable and controllable extrusion-based 3D-printing system, the extrudability, shape-holdability and fracture resistance not only need fully mathematical representations but also need wholly enabling technologies. As far as we know, this synthetic framework is the first attempt to provide a fully mathematical survey for the extrusion-based 3D-printing process while most of previous research work mainly focused on one point [ 47 , 48 , 49 , 50 ].…”

Section: Extrusion-based 3d-printing Methods With In Situ Hot Air Fmentioning

confidence: 99%

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

Mikołajczyk

Pimenov

et al. 2021

Materials

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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.

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Section: Extrusion-based 3d-printing Methods With In Situ Hot Air Fmentioning

confidence: 99%

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

Mikołajczyk

Pimenov

et al. 2021

Materials

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“…Freeform structures refer to complex geometry buildings and their resisting and non-resisting structural parts [ 128 ]. They are desirable in architecture since their curvature may withstand higher lateral forces, and less material is needed when compared with straight walls [ 28 , 128 , 165 , 166 ]. To produce a freeform structure, in some cases, such as with composite materials, a molding process is usually needed.…”

Section: Biomimicry-based Manufacturing Techniquesmentioning

confidence: 99%

Environmentally Responsive Materials for Building Envelopes: A Review on Manufacturing and Biomimicry-Based Approaches

2023

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Buildings must adapt and respond dynamically to their environment to reduce their energy loads and mitigate environmental impacts. Several approaches have addressed responsive behavior in buildings, such as adaptive and biomimetic envelopes. However, biomimetic approaches lack sustainability consideration, as conducted in biomimicry approaches. This study provides a comprehensive review of biomimicry approaches to develop responsive envelopes, aiming to understand the connection between material selection and manufacturing. This review of the last five years of building construction and architecture-related studies consisted of a two-phase search query, including keywords that answered three research questions relating to the biomimicry and biomimetic-based building envelopes and their materials and manufacturing and excluding other non-related industrial sectors. The first phase focused on understanding biomimicry approaches implemented in building envelopes by reviewing the mechanisms, species, functions, strategies, materials, and morphology. The second concerned the case studies relating to biomimicry approaches and envelopes. Results highlighted that most of the existing responsive envelope characteristics are achievable with complex materials requiring manufacturing processes with no environmentally friendly techniques. Additive and controlled subtractive manufacturing processes may improve sustainability, but there is still some challenge to developing materials that fully adapt to large-scale and sustainability needs, leaving a significant gap in this field.

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“…Multi-modal particle distributions; as the powder that is used, are often preferred when making ceramic formulations for additive manufacturing, since the combination of big and small particles within the suspension, often exhibit a more desirable rheological behaviour such as high solid content and lower viscosity [30,31] and reduced shrinkage during drying [32], compared to unimodal distributions. Additionally, this has been found to have a positive effect with sintering, as the smaller particles are expected to fill in any intra-granular gaps formed in between the larger grains and lead to improved packing densification and mechanical properties [32][33][34][35].…”

Section: Raw Materials Characterisationmentioning

confidence: 99%

Direct ink writing of bismuth molybdate microwave dielectric ceramics

Goulas

Chi-Tangyie

Zhang

et al. 2021

Ceramics International

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Influence of formulation parameters on the freeform extrusion process of ceramic pastes and resulting product properties

Cited by 10 publications

References 22 publications

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

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

Environmentally Responsive Materials for Building Envelopes: A Review on Manufacturing and Biomimicry-Based Approaches

Direct ink writing of bismuth molybdate microwave dielectric ceramics

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