Synergy of solid loading and printability of ceramic paste for optimized properties of alumina via stereolithography-based 3D printing

Liu, Weiwei; Li, Maoshan; Nie, Jianbin; Wang, Chuanyang; Li, Wenli

doi:10.1016/j.jmrt.2020.08.038

Cited by 47 publications

(13 citation statements)

References 20 publications

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“…Additive manufacturing technology offers a novel solution to the challenges of lengthy production cycles and the complexities associated with preparing highly intricate structures using traditional processing methods 6–8 . According to its development order, it is divided into stereo lithography apparatus technology and digital light processing (DLP) technology 5,9–12 . DLP ceramic molding technology is actually a mask‐based surface exposure technique.…”

Section: Introductionmentioning

confidence: 99%

“…[6][7][8] According to its development order, it is divided into stereo lithography apparatus technology and digital light processing (DLP) technology. 5,[9][10][11][12] DLP ceramic molding technology is actually a mask-based surface exposure technique. A light source is employed to illuminate the printed shape of each layer onto the surface of the photosensitive resin using a mask, facilitating the gradual solidification of each layer individually.…”

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confidence: 99%

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3D printing of high solid Al₂O₃ ceramics based on green and renewable photosensitive resin with low viscosity and low shrinkage

Yao,

Hu,

et al. 2024

Polymers for Advanced Techs

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A low‐viscosity bio‐based carbamate acrylate was synthesized by the reaction of pentamethylene diisocyanate derived from pentanediamine with a low molecular weight acrylate hydroxyl ester. The carbamate acrylate was used in the 3D printing of ceramics, and a correlation between the solid content and viscosity of the ceramic slurry was observed. The ceramic slurry exhibits good stability and low shrinkage. The results indicate that the viscosity of the ceramic slurry was 2.11 Pa s with a solid content of 80 wt%, which makes it suitable for digital light processing printing. In addition, a new type of photoinitiator called (2,4,6‐trimethylbenzoyl)bis(p‐tolyl)phosphine oxide (TMO) has been applied, demonstrating excellent potential in ceramic slurry. According to its thermogravimetric curve, a debinding and sintering process was designed, and ultimately an Al2O3 device with a density of 94.49% was prepared.

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Section: Introductionmentioning

confidence: 99%

mentioning

confidence: 99%

3D printing of high solid Al₂O₃ ceramics based on green and renewable photosensitive resin with low viscosity and low shrinkage

Yao,

Hu,

et al. 2024

Polymers for Advanced Techs

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“…The composition of commercial pastes is however kept confidential and the numerous variables investigated in the academic literature 11,12 makes it quite difficult to extract a canonical recipe where the role of each ingredient on rheological and curing properties is clearly identified. Promising work mainly based on rheological flow curves consisting of following the steady-shear viscosity in the permanent regime as a function of the shear rate (η = f ( γ)) have nevertheless been published on the impact of dispersants and plasticizers [11][12][13][14] .…”

Section: Introductionmentioning

confidence: 99%

Spreading ceramic stereolithography pastes: Insights from shear- and orthogonal-rheology

Fournier,

Chevalier,

Perez-Robles

et al. 2023

Journal of Rheology

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We study the shear rheological behavior of a commercial stereolithography paste containing ≈50 vol. % of zirconia particles (diameter ≈ 100 nm) with the aim to clarify physical mechanisms occurring during the “scraping” step of this yield stress fluid. Beyond a flow curve characterized by a high zero-shear viscosity accompanied with an overall shear-thinning behavior, we investigate in a systematic way the transient regime through start-up experiments. We demonstrate that a structural transition occurs between 10−2 and 10−1 s−1, resulting in an apparent interruption of the shear-thinning. The corresponding transient response presents a pronounced extra-growth of the shear stress before to stabilize at high strain amplitude and a negative first normal stress difference peak, both effects become stronger at higher shear rates. These observations are rationalized based on the high interparticle friction owing to the polyhedral shape and the roughness of the particles. In addition, relaxation tests following the start-up experiments reveal that the samples submitted to shear rates higher than 10−1 s−1 cannot relax the shear stress to the same level as in low shear rate experiments, suggesting a durable structural modification likely to impact the quality of the parts prior to their debinding and densification. Finally, we utilize orthogonal superposition rheology to illustrate how the application of an oscillatory deformation during the scraping procedure could help to reduce the shear-thinning interruption and improve the stereolithography processing as already observed empirically during scraping.

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“…Ceramic paste composition is an important consideration for stereolithography. The solid content of the paste has a significant impact on processability and part properties [15]. A solid loading of greater than 50% is recommended to prevent the cracking of parts during binder removal and reduce shrinkage during sintering [16].…”

Section: Introductionmentioning

confidence: 99%

High-Speed Alumina Stereolithography

2022

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The additive manufacturing of ceramics offers a reliable and repeatable method for fabricating parts with complex geometries. To compete with conventional ceramic forming methods, the time and cost associated with material and process optimization for ceramic stereolithography should be improved. Computational analysis methods can be utilized to reduce the number of experimental steps required for material and process optimization. This work used the discrete element method and ray tracing analyses to predict suitable material parameters and processing conditions for ceramic stereolithography. The discrete element method was used to create alumina particle dispersion models to predict suitable paste compositions, and ray tracing was used to predict suitable laser power and scan speed to achieve a sufficient curing depth for stereolithography processing. The predicted conditions of paste composition and processing parameters were comparable to experimental values, reducing the number of experimental iterations required for process optimization. Furthermore, suitable processing parameters for high-speed fabrication by stereolithography was predicted, achieving a processing speed much faster than previously reported ceramic stereolithography. The reduction in process optimization timeline, and the increase in fabrication speed, could increase the appeal of ceramic stereolithography to industry.

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Synergy of solid loading and printability of ceramic paste for optimized properties of alumina via stereolithography-based 3D printing

Cited by 47 publications

References 20 publications

3D printing of high solid Al₂O₃ ceramics based on green and renewable photosensitive resin with low viscosity and low shrinkage

3D printing of high solid Al₂O₃ ceramics based on green and renewable photosensitive resin with low viscosity and low shrinkage

Spreading ceramic stereolithography pastes: Insights from shear- and orthogonal-rheology

High-Speed Alumina Stereolithography

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Synergy of solid loading and printability of ceramic paste for optimized properties of alumina via stereolithography-based 3D printing

Cited by 47 publications

References 20 publications

3D printing of high solid Al2O3 ceramics based on green and renewable photosensitive resin with low viscosity and low shrinkage

3D printing of high solid Al2O3 ceramics based on green and renewable photosensitive resin with low viscosity and low shrinkage

Spreading ceramic stereolithography pastes: Insights from shear- and orthogonal-rheology

High-Speed Alumina Stereolithography

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Product

Resources

About

3D printing of high solid Al₂O₃ ceramics based on green and renewable photosensitive resin with low viscosity and low shrinkage

3D printing of high solid Al₂O₃ ceramics based on green and renewable photosensitive resin with low viscosity and low shrinkage