Advanced Ceramics Progress

Advanced Ceramics Progress

Investigating the Effect of Modifying the Binder and Other Additives on the Printability of Ceramic Paste for the Direct Ink Writing (DIW) Technique

Document Type : Original Research Article

Authors
Shahram Mahboubizadeh 1
Arqavan Kazemi 2
Mehdi Khodaei 3
1 PhD Candidate, Department of Materials Engineering, Science and Research Branch, Islamic Azad University,Tehran, Iran.
2 Assistant Professor, Department of Materials Engineering, Science and Research Branch, Islamic Azad University,Tehran, Iran.
3 Associate Professor, Faculty of Material Science and Engineering, K. N. Toosi University of Technology, Tehran, Iran.
10.30501/acp.2025.486901.1169
Abstract
Ceramic 3D printing, also known as ceramic additive manufacturing, is one of the new production methods based on 3D printers without the need for molds. This manufacturing method allows for the creation of ceramics with complex geometric shapes, hence cost reduction. Among the various additive manufacturing methods, extrusion-based printers have been well received by a large number of researchers and industrialists. In this study, the rheological behavior of ceramic pastes and their printability in the extrusion-based 3D printing process were investigated. Emphasis is placed on optimizing the parameters that affect paste printing, particularly for pastes containing a high weight percentage (wt%) of alumina powder. The current research used Direct Ink Writing (DIW) method to examine the impact of adjusting binder content and additives such as plasticizers and dispersants on the printability of the alumina paste. The results indicate that optimizing these parameters improves the printability of the paste which exhibited shear thinning behavior. Paste samples with varying weight percentages of alumina powder and Polyvinyl Alcohol (PVA) binder were prepared. After evaluating their printability and viscosity, the printing process was carried out. The printed samples were then sintered at a temperature of 1250 °C. The results revealed that increasing the printability of alumina pastes enhanced their density and strength. The best results were achieved with a 70 wt% alumina sample, which exhibited a density of 1.8 g/cm³ and a flexural strength of 2.9 MPa. These results confirm the significant influence of  wt% of alumina powder on the mechanical properties of the printed parts.
Keywords
Additive Manufacturing
Robocasting
Direct Ink Writing (DIW)
Alumina
3D Printer

Subjects

  1. Abbasian, A. R., & Omidvar-Askary, N. (2018). The optimization of dispersant content in alumina castable containing nano-titania. Advanced Ceramics Progress, 4(3-4), 16-22.. https://doi.org/10.30501/acp.2018.92944
  2. Ananthakumar, S., Manohar, P., & Warrier, K. G. K. (2004). Effect of boehmite and organic binders on extrusion of alumina. Ceramics International, 30(6), 837–842. https://doi.org/10.1016/j.ceramint.2003.09.019
  3. Bae, C. J., Ramachandran, A., & Halloran, J. W. (2018). Quantifying particle segregation in sequential layers fabricated by additive manufacturing. Journal of the European Ceramic Society, 38(11), 4082-4088. https://doi.org/10.1016/j.jeurceramsoc.2018.02.008
  4. Balla, V. K., Bose, S., & Bandyopadhyay, A. (2008). Processing of bulk alumina ceramics using laser engineered net shaping. International Journal of Applied Ceramic Technology, 5(3), 234–242. https://doi.org/10.1111/J.1744-7402.2008.02202.X
  5. Cawley, J. D., Wei, P., Liu, Z. E., Newman, W. S., Mathewson, B. B., & Heuer, A. H. (1995). Al2O3 ceramics made by CAM-LEM (computer-aided manufacturing of laminated engineering materials) technology. https://repositories.lib.utexas.edu/handle/2152/68681
  6. Cesarano TIl, J., Baer, T. A., & Calvert, P. (1997). Recent developments in freeform fabrication of dense ceramics from slurry deposition. https://repositories.lib.utexas.edu/handle/2152/70322
  7. Chen, Z., Li, Z., Li, J., Liu, C., Lao, C., Fu, Y., Liu, C., Li, Y., Wang, P., & He, Y. (2019). 3D printing of ceramics: A review. Journal of the European Ceramic Society, 39(4), 661-687. https://doi.org/10.1016/j.jeurceramsoc.2018.11.013
  8. del-Mazo-Barbara, L., & Ginebra, M. P. (2021). Rheological characterisation of ceramic inks for 3D direct ink writing: A review. Journal of the European Ceramic Society, 41(16), 18–33. https://doi.org/10.1016/j.jeurceramsoc.2021.08.031
  9. Farzadi, A., Waran, V., Solati-Hashjin, M., Rahman, Z. A. A., Asadi, M., & Osman, N. A. A. (2015). Effect of layer printing delay on mechanical properties and dimensional accuracy of 3D printed porous prototypes in bone tissue engineering. Ceramics International, 41(7), 8320-8330. https://doi.org/10.1016/j.ceramint.2015.03.004
  10. Feilden, E., Ferraro, C., Zhang, Q., García-Tuñón, E., D’Elia, E., Giuliani, F., Vandeperre, L., & Saiz, E. (2017). 3D Printing Bioinspired Ceramic Composites. Scientific Reports, 7(1). https://doi.org/10.1038/s41598-017-14236-9
  11. Flores-Martinez, N., Remondiere, F., Jouin, J., Fiore, G., Oriol, S., & Rossignol, S. (2022). Aluminum concentration range for the extrudability of ceramic pastes. Open Ceramics, 9, 100213. https://doi.org/10.1016/j.oceram.2021.100213
  12. Fu, Z., Freihart, M., Wahl, L., Fey, T., Greil, P., & Travitzky, N. (2017). Micro- and macroscopic design of alumina ceramics by robocasting. Journal of the European Ceramic Society, 37(9), 3115–3124. https://doi.org/10.1016/j.jeurceramsoc.2017.03.052
  13. Gao, C., Yang, B., Hu, H., Liu, J., Shuai, C., & Peng, S. (2013). Enhanced sintering ability of biphasic calcium phosphate by polymers used for bone scaffold fabrication. Materials Science and Engineering: C, 33(7), 3802-3810. https://doi.org/10.1016/j.msec.2013.05.017
  14. Glymond, D., & Vandeperre, L. J. (2018). Robocasting of MgO-doped alumina using alginic acid slurries. Journal of the American Ceramic Society, 101(8), 3309–3316. https://doi.org/10.1111/jace.15509
  15. Grau, J. E. (1998). Fabrication of engineered ceramic components by the slurry-based three dimensional printing process (Doctoral dissertation, Massachusetts Institute of Technology). https://dspace.mit.edu/handle/1721.1/9584
  16. Hao, L., Dadbakhsh, S., Seaman, O., & Felstead, M. (2009). Selective laser melting of a stainless steel and hydroxyapatite composite for load-bearing implant development. Journal of materials processing technology, 209(17), 5793-5801 https://doi.org/10.1016/j.jmatprotec.2009.06.012
  17. Huang, T., Mason, M. S., Hilmas, G. E., & Leu, M. C. (2006). Freeze-form extrusion fabrication of ceramic parts. Virtual and Physical Prototyping, 1(2), 93–100. https://doi.org/10.1080/17452750600649609
  18. Khecho, A., Ghaffari, S. A., Behzadnasab, M., & Rahmat, M. (2021). Preparation of High-Solid Filled Alumina Inks for Stereolithography 3D Printing Process. Advanced Ceramics Progress, 7(2), 23–27. https://doi.org/10.30501/acp.2021.287468.1062
  19. Lakhdar, Y., Tuck, C., Binner, J., Terry, A., & Goodridge, R. (2021). Progress in Materials Science Additive manufacturing of advanced ceramic materials. Progress in Materials Science, 116(August 2020), 100736. https://doi.org/10.1016/j.pmatsci.2020.100736
  20. Lamnini, S., Elsayed, H., Lakhdar, Y., Baino, F., Smeacetto, F., & Bernardo, E. (2022). Robocasting of advanced ceramics: ink optimization and protocol to predict the printing parameters - A review. Heliyon, 8(9). https://doi.org/10.1016/j.heliyon.2022.e10651
  21. Landek, D., Ćurković, L., Gabelica, I., Mustafa, M. K., & Žmak, I. (2021). Optimization of sintering process of alumina ceramics using response surface methodology. Sustainability (Switzerland), 13(12). https://doi.org/10.3390/su13126739
  22. Lee, M. P., Cooper, G. J., Hinkley, T., Gibson, G. M., Padgett, M. J., & Cronin, L. (2015). Development of a 3D printer using scanning projection stereolithography. Scientific reports, 5(1), 9875 https://www.nature.com/articles/srep09875
  23. Lee, S., Lee, C. Y., Ha, J. H., Lee, J., Song, I. H., & Kwon, S. H. (2021). Enhancing compressive strength of reticulated porous alumina by optimizing processing conditions. Applied Sciences (Switzerland), 11(10). https://doi.org/10.3390/app11104517
  24. Maillard, M., Chevalier, J., Gremillard, L., Baeza, G. P., Courtial, E. J., Marion, S., & Garnier, V. (2023). Optimization of mechanical properties of robocast alumina parts through control of the paste rheology. Journal of the European Ceramic Society, 43(7), 2805–2817. https://doi.org/10.1016/j.jeurceramsoc.2022.12.008
  25. Mamatha, S., Biswas, P., Ramavath, P., Das, D., & Johnson, R. (2021). Effect of parameters on 3D printing of alumina ceramics and evaluation of properties of sintered parts. Journal of Asian Ceramic Societies. https://doi.org/10.1080/21870764.2021.1920159
  26. Minas, C., Carnelli, D., Tervoort, E., & Studart, A. R. (2016). 3D Printing of Emulsions and Foams into Hierarchical Porous Ceramics. Advanced Materials, 28(45), 9993–9999. https://doi.org/10.1002/adma.201603390
  27. Morissette, S. L., Lewis, J. A., Cesarano, J., Dimos, D. B., & Baer, T. (2000). Solid freeform fabrication of aqueous alumina-poly(vinyl alcohol) gelcasting suspensions. Journal of the American Ceramic Society, 83(10), 2409–2416. https://doi.org/10.1111/j.1151-2916.2000.tb01569.x
  28. Nampi, P. P., Kume, S., Hotta, Y., Watari, K., Itoh, M., Toda, H., & Matsutani, A. (2011). The effect of polyvinyl alcohol as a binder and stearic acid as an internal lubricant in the formation, and subsequent sintering of spray-dried alumina. Ceramics International, 37(8), 3445–3450. https://doi.org/10.1016/j.ceramint.2011.05.149
  29. Nie, J., Li, M., Liu, W., Li, W., & Xing, Z. (2021). The role of plasticizer in optimizing the rheological behavior of ceramic pastes intended for stereolithography-based additive manufacturing. Journal of the European Ceramic Society, 41(1), 646–654. https://doi.org/10.1016/j.jeurceramsoc.2020.08.013
  30. Okyay, C., & Sağbaş, B. (2021). Determining Optimal Robocasting Process Parameters for Additive Manufacturing of Ceramic Parts. International Journal of 3D Printing Technologies and Digital Industry, 5(3), 435–444. https://doi.org/10.46519/ij3dptdi.904697
  31. Onagoruwa, S., Bose, S., & Bandyopadhyay, A. (2001). Fused deposition of ceramics (FDC) and composites. http://dx.doi.org/10.26153/tsw/3267
  32. Rane, K., & Strano, M. (2019). A comprehensive review of extrusion-based additive manufacturing processes for rapid production of metallic and ceramic parts. Advances in Manufacturing, 7, 155-173. https://doi.org/10.1007/s40436-019-00253-6
  33. Rueschhoff, L., Costakis, W., Michie, M., Youngblood, J., & Trice, R. (2016). Additive manufacturing of dense ceramic parts via direct ink writing of aqueous alumina suspensions. International Journal of Applied Ceramic Technology, 13(5), 821-830. https://doi.org/10.1111/ijac.12557
  34. Schlordt, T., Keppner, F., Travitzky, N., & Greil, P. (2012). Robocasting of alumina lattice truss structures. Journal of Ceramic Science and Technology, 3(2), 81-87. https://doi.org/10.1016/j.jmatprotec.2013.03.014
  35. Shahzad, K., Deckers, J., Kruth, J., Materials, J. V.-J. of, & 2013‏, (n.d.). Additive manufacturing of alumina parts by indirect selective laser sintering and post processing‏. Elsevier‏. Retrieved January 11, 2022, from https://doi.org/10.1016/j.jmatprotec.2013.03.014
  36. Weisensel, L., Travitzky, N., Sieber, H., & Greil, P. (2004). Laminated Object Manufacturing (LOM) of SiSiC composites. Advanced Engineering Materials, 6(11), 899–903. https://doi.org/10.1002/ADEM.200400112
  37. Wu, Y., Tang, R., Guo, A., Tao, X., Hu, Y., Sheng, X., Qu, P., Wang, S., Li, J., & Li, F. (2023). Enhancing Starch−Based Packaging Materials: Optimization of Plasticizers and Process Parameters. Materials, 16(17). https://doi.org/10.3390/ma16175953
  38. Xia, Y., Lu, Z., Cao, J., Miao, K., Li, J., & Li, D. (2019). Microstructure and mechanical property of Cf/SiC core/shell composite fabricated by direct ink writing. Scripta Materialia, 165, 84–88. https://doi.org/10.1016/J.SCRIPTAMAT.2019.02.016
  39. Xiaotong Fang, Yu Zu, Q. M. & J. H. (2023). State of the art of metal powder bonded binder jetting printing technology. Discover Materials, 3(1), 15. https://doi.org/10.1007/s43939-023-00050-w

  • Receive Date 03 November 2024
  • Revise Date 26 November 2024
  • Accept Date 04 January 2025