Ceramika drukowana w 3D – możliwości i ograniczenia w formowaniu przyrostowym wyrobów ceramicznych

• Autorzy: Tańska Joanna , Więcław-Midor Anna , Falkowski Paweł , Wiecińska Paulina

Warianty tytułu

3D printing of ceramics - possibilities and limitations in additive manufacturing of ceramic parts

• Języki publikacji: PL

Abstrakty

PL

Dynamiczny rozwój technik formowania przyrostowego, obserwowany na przestrzeni ostatnich lat, świadczy o istniejącej potrzebie na wytwarzanie złożonych i precyzyjnych elementów bez stosowania form odlewniczych. Konieczność dopasowania produktu do indywidualnych potrzeb wymusza powstawanie coraz to nowych technik druku 3D, a także dostosowywanie ich do wytwarzania wyrobów z różnego rodzaju materiałów, m.in. z ceramiki. W artykule przedstawiono zarys historyczny metod druku 3D i ich podział zgodnie z normą ISO/ASTM 52900, a także opisano poszczególne grupy metod oraz przykładowe techniki wchodzące w ich skład. Podczas wyboru techniki formowania dla danego produktu należy wziąć pod uwagę wiele czynników, takich jak rodzaj stosowanego materiału, wymiary produktu czy oczekiwana rozdzielczość. Drukowanie materiałów ceramicznych wciąż stanowi duże wyzwanie dla badaczy, gdyż nie można bezpośrednio przełożyć procesów zachodzących dla polimerów na ceramikę, chociażby ze względu na wysokie temperatury topnienia materiałów ceramicznych. Dodatkowo, w przypadku metod druku 3D wykorzystujących procesy fotoutwardzania (np. w technice DLP (cyfrowego przetwarzania światła), konieczne jest przygotowanie zawiesiny proszku ceramicznego z dodatkiem monomerów i fotoinicjatora. W tej metodzie selektywnie utwardza się powierzchnię zawiesiny warstwa po warstwie przy pomocy światła UV. Niestety, cząstki proszku ceramicznego rozpraszają oraz pochłaniają promieniowanie UV, co znacząco obniża głębokość sieciowania, czyli maksymalną głębokość, na jaką wnika promieniowanie, dostarczając energii niezbędnej do zainicjowania reakcji polimeryzacji. W związku z tym proszek ceramiczny powinien charakteryzować się zbliżoną wartością współczynnika załamania światła do zastosowanej żywicy. Ponadto w przypadku materiałów ceramicznych, ważnym etapem procesu ich otrzymywania, poza formowaniem, jest również spiekanie. Odpowiedni dobór poszczególnych parametrów prowadzenia procesu spiekania, takich jak temperatura spiekania i czas przetrzymania czy szybkość ogrzewania i chłodzenia, jest kluczowy, aby wydrukowane wyroby nie uległy pękaniu i były dobrze zagęszczone. W niniejszym artykule przedstawiono najważniejsze problemy związane z otrzymywaniem ceramiki metodą druku DLP oraz przykładowe ich rozwiązania.

EN

The dynamic development of additive manufacturing techniques, observed in recent years, is related to the need for the production of complex and precise elements without the use of casting moulds. Adjusting the product to individual needs forces the development of new 3D printing techniques, as well as adapting them to the production of elements from various types of materials, including ceramics. The article presents a historical outline of 3D printing methods and their division according to the ISO/ASTM 52900 standard, as well as it describes individual groups of methods and exemplary techniques included in them. There are many factors to consider when choosing an appropriate moulding technique, such as the type of material used, product dimensions, and desired resolution. Printing ceramic materials is still a big challenge for researchers because the processes used for polymers cannot be directly transferred into ceramics, for example because of the high melting points of ceramic materials. In addition, in case of 3D printing methods that use photocuring processes (e.g. in the DLP (digital light processing) technique, it is necessary to prepare a suspension of ceramic powder with the addition of monomers and a photoinitiator. In this method, the surface of the slurry is selectively cured layer by layer with UV light. Unfortunately, the ceramic powder particles scatter and absorb UV radiation which significantly reduces the cure depth, i.e. the maximum depth to which the radiation penetrates, providing enough energy to initiate the polymerization reaction. Therefore, the ceramic powder should have a refractive index similar to the used resin. In addition, in the case of ceramic materials, sintering is also an important step. Appropriate selection of individual parameters of the sintering process, such as sintering temperature and dwell time, or the rate of heating and cooling, is crucial to obtain well densified and undefected printed parts. This article presents the most important problems related to obtaining ceramics by DLP printing and exemplary solutions.

Słowa kluczowe

PL

formowanie przyrostowe; druk 3D; cyfrowe przetwarzanie światła; fotoutwardzalna dyspersja ceramiczna

EN

additive manufacturing; 3D printing; digital light processing; photocurable ceramic dispersion

• Wydawca: Sieć Badawcza Łukasiewicz - Instytut Ceramiki i Materiałów Budowlanych
• Czasopismo: Szkło i Ceramika
• Rocznik: 2023
• Tom: R. 74, nr 2
• Strony: 34--42
• Opis fizyczny: Bibliogr. 47 poz., rys., tab., wykr.

Twórcy

autor

Tańska Joanna

• Wydział Chemiczny, Politechnika Warszawska, Noakowskiego 3, 00-664 Warszawa

• https://orcid.org/0000-0001-6772-7536

autor

Więcław-Midor Anna

• Wydział Chemiczny, Politechnika Warszawska, Noakowskiego 3, 00-664 Warszawa

• https://orcid.org/0000-0003-3395-2596

autor

Falkowski Paweł

• Wydział Chemiczny, Politechnika Warszawska, Noakowskiego 3, 00-664 Warszawa

autor

Wiecińska Paulina

• Wydział Chemiczny, Politechnika Warszawska, Noakowskiego 3, 00-664 Warszawa

• https://orcid.org/0000-0003-3553-1461

Bibliografia

• 1 J. Deckers, J. Vleugels, J.P. Kruth, Additive manufacturing of ceramics: A review, J Ceram Sci Technol 2014, 5, p. 245–260. https://doi.org/10.4416/JCST2014-00032
• 2 Y. Lakhdar, C. Tuck, J. Binner, A. Terry, R. Goodridge, Additive manufacturing of advanced ceramic materials, Prog Mater Sci 2021, 116, 100736. https://doi.org/10.1016/j.pmatsci.2020.100736
• 3 T.D. Ngo, A. Kashani, G. Imbalzano, K.T.Q. Nguyen, D. Hui, Additive manufacturing (3D printing): A review of materials, methods, applications and challenges. Compos Part B Eng 2018, 143, p. 172–196. https://doi.org/10.1016/j.compositesb.2018.02.012
• 4 Z. Xia, S. Jin, K. Ye, Tissue and Organ 3D Bioprinting, SLAS Technol 2018, 23, p. 301–314. https://doi.org/10.1177/2472630318760515
• 5 J.S. Pelz, N. Ku, M.A. Meyers, L.R. Vargas-Gonzalez, Additive manufacturing of structural ceramics: a historical perspective. J Mater Res Technol 2021, 15, p. 670–695. https://doi.org/10.1016/j.jmrt.2021.07.155
• 6 S.C. Altıparmak, V.A. Yardley, Z. Shi, J. Lin, Extrusion-based additive manufacturing technologies: State of the art and future perspectives. J Manuf Process 2022, 83, p. 607–636. https://doi.org/10.1016/j.jmapro.2022.09.032
• 7 M. Ziaee, N.B. Crane, Binder jetting: A review of process, materials, and methods, Addit Manuf 2019, 28, p. 781–801. https://doi.org/10.1016/j.addma.2019.05.031
• 8 F. Calignano, D. Manfredi, E.P. Ambrosio, S. Biamino, M. Lombardi, E. Atzeni, et al, Overview on additive manufacturing technologies, Proc IEEE 2017, 105, p. 593–612. https://doi.org/10.1109/JPROC.2016.2625098
• 9 ASTM International. INTERNATIONAL STANDARD ISO/ASTM 52900 Additive manufacturing — General principles — Terminology, 2015.
• 10 Y. Huang, D. Wu, D. Zhao, F. Niu, G. Ma, Investigation of melt-growth alumina/aluminum titanate composite ceramics prepared by directed energy deposition. Int J Extrem Manuf 2021, 3, 035101. https://doi.org/10.1088/2631-7990/abf71a
• 11 U. Chadha, S.K. Selvaraj, A.S. Lamsal, Y. Maddini, A.K. Ravinuthala, B. Choudhary, et al., Directed Energy Deposition via Artificial Intelligence-Enabled Approaches. Complexity 2022, 2022, p. 1–32. https://doi.org/10.1155/2022/2767371
• 12 H. Liu, H. Su, Z. Shen, D. Zhao, Y. Liu, Y. Guo, et al., One-step additive manufacturing and microstructure evolution of melt-grown Al2 O3 /GdAlO3 /ZrO2 eutectic ceramics by laser directed energy deposition, J Eur Ceram Soc 2021, 41, p. 3547–3558. https://doi.org/10.1016/j.jeurceramsoc.2021.01.047
• 13 F. Niu, S. Yan, G. Ma, D. Wu, Directed-Energy Deposition for Ceramic Additive Manufacturing, Addit Manuf Process 2020, p. 131–151. https://doi.org/10.31399/asm.hb.v24.a0006559
• 14 C. Huo, X. Tian, Y. Nan, D. Li, Journal of the European Ceramic Society Hierarchically porous alumina ceramic catalyst carrier prepared by powder bed fusion, J Eur Ceram Soc 2020, 40, p. 4253–4264. https://doi.org/10.1016/j.jeurceramsoc.2020.03.059
• 15 F. Verga, M. Borlaf, L. Conti, K. Florio, M. Vetterli, T. Graule, et al., Laser-based powder bed fusion of alumina toughened zirconia, Addit Manuf 2020, 31, p. 100959. https://doi.org/10.1016/j.addma.2019.100959
• 16 K. Florio, D. Puccio, G. Viganò, S. Pfeiffer, F. Verga, M. Grasso, et al., Process characterization and analysis of ceramic powder bed fusion, Int J Adv Manuf Technol 2021, 117, p. 2105–2116. https://doi.org/10.1007/s00170-021-07625-y
• 17 R. Singh, A. Gupta, O. Tripathi, S. Srivastava, B.Singh, A. Awasthi, Materials Today: Proceedings Powder bed fusion process in additive manufacturing, An overview, Mater Today Proc 2020, 26, p. 3058–3070. https://doi.org/10.1016/j.matpr.2020.02.635
• 18 X. Lv, F. Ye, L. Cheng, S. Fan, Y. Liu, Binder jetting of ceramics: Powders, binders, printing parameters, equipment, and post-treatment, Ceram Int 2019, 45, p. 12609–12624. https://doi.org/10.1016/j.ceramint.2019.04.012
• 19 M. Mariani, R. Beltrami, P. Brusa, C. Galassi, R. Ardito, N. Lecis, Journal of the European Ceramic Society 3D printing of fine alumina powders by binder jetting, J Eur Ceram Soc 2021, 41, p. 5307–5315. https://doi.org/10.1016/j.jeurceramsoc.2021.04.006
• 20 W. Du, X. Ren, Z. Pei, C. Ma, Ceramic Binder Jetting Additive Manufacturing:
• A Literature Review on Density, J Manuf Sci Eng 2020, 142, p. 1–19. https://doi.org/10.1115/1.4046248
• 21 Y. Zhang, X. He, J. Han, S. Du, J. Zhang, Al2O3 Ceramics Preparation by LOM (Laminated Object Manufacturing), Int J Adv Manuf Technol 2001, p. 531–534
• 22 D.A. Klosterman, R.P. Chartoff, N.R. Osborne, G.A. Graves, A. Lightman, G. Han, et al., Curved Layer LOM of Ceramics and Composites n.d., p. 671–680
• 23 H. Hur, Y.J. Park, D. Kim, J.W. Ko, Materials & Design Material extrusion for ceramic additive manufacturing with polymer-free ceramic precursor binder, Mater Des 2022, 221, p. 110930. https://doi.org/10.1016/j.matdes.2022.110930
• 24 F. Clemens, F. Sarraf, A. Borzì, A. Neels, A. Hadian, Material extrusion additive manufacturing of advanced ceramics: Towards the production of large components, J Eur Ceram Soc 2022. https://doi.org/10.1016/j.jeurceramsoc.2022.10.019
• 25 A. Hadian, L. Koch, P. Koberg, F. Sarraf, A. Liersch, T. Sebastian, et al., Material extrusion based additive manufacturing of large zirconia structures using filaments with ethylene vinyl acetate based binder composition. Addit Manuf 2021, 47, p. 102227. https://doi.org/10.1016/j.addma.2021.102227
• 26 J. Gonzalez-Gutierrez, S. Cano, S. Schuschnigg, C. Kukla, J. Sapkota, C. Holzer, Additive Manufacturing of Metallic and Ceramic Components by the Material Extrusion of Highly-Filled Polymers: A Review and Future Perspectives, Materials (Basel) 2018, 11, p. 840. https://doi.org/10.3390/ma11050840
• 27 A. Shahzad, I. Lazoglu, Direct ink writing (DIW) of structural and functional ceramics: Recent achievements and future challenges, Compos Part B Eng 2021, 225, p. 109249. https://doi.org/10.1016/j.compositesb.2021.109249
• 28 G. Franchin, L. Wahl, P. Colombo, Direct ink writing of ceramic matrix composite structures. J Am Ceram Soc 2017, 100, p. 4397–4401. https://doi.org/10.1111/jace.15045
• 29 E. Willems, M. Turon-Vinas, B. Camargo, B. Van Hooreweder, F. Zhang, Journal of the European Ceramic Society Additive manufacturing of zirconia ceramics by material jetting, J Eur Ceram Soc 2021, 41, p. 5292–5306. https://doi.org/10.1016/j.jeurceramsoc.2021.04.018
• 30 H. Fayazfar, F. Liravi, U. Ali, E. Toyserkani, Additive manufacturing of high loading concentration zirconia using high-speed drop-on-demand material jetting. Int J Adv Manuf Technol 2020, 109, p. 2733–2746. https://doi.org/10.1007/s00170-020-05829-2
• 31 V. Lang, S. Weingarten, H. Wiemer, U. Scheithauer, F. Glausch, R. Johne, et al., Process Data-Based Knowledge Discovery in Additive Manufacturing of Ceramic Materials by Multi-Material Jetting (CerAM MMJ). J Manuf Mater Process 2020, 4, p. 74. https://doi.org/10.3390/jmmp4030074
• 32 S. Tyagi, A. Yadav, S. Deshmukh, Materials Today: Proceedings Review on mechanical characterization of 3D printed parts created using material jetting process, Mater Today Proc 2022, 51, p. 1012–1016. https://doi.org/10.1016/j.matpr.2021.07.073
• 33 I. Leite, D. Camargo, M. Mota, C. Alberto, M. Cristina, A review on the rheological behavior and formulations of ceramic suspensions for vat photopolymerization. Ceram Int 2021, 47, 11906–11921. https://doi.org/10.1016/j.ceramint.2021.01.031
• 34 F. Zhang, L. Zhu, Z. Li, S. Wang, J. Shi, W. Tang, et al. The recent development of vat photopolymerization: A review, Addit Manuf 2021, 48, p. 102423. https://doi.org/10.1016/j.addma.2021.102423
• 35 X. Li, Y. Chen, Vat-Photopolymerization-Based Ceramic Manufacturing. J Mater Eng Perform 2021, 30, p. 4819–4836. https://doi.org/10.1007/s11665-021-05920-z
• 36 G. Franchin, H. Elsayed, R. Botti, K. Huang, J. Schmidt, G. Giometti, et al. Additive Manufacturing of Ceramics from Liquid Feedstocks, Chinese J Mech Eng Addit Manuf Front 2022, 1, p. 100012. https://doi.org/10.1016/J.CJMEAM.2022.100012
• 37 R. He, W. Liu, Z. Wu, D. An, M. Huang, H. Wu, et al. Fabrication of complex-shaped zirconia ceramic parts via a DLP-stereolithography-based 3D printing method, Ceram Int 2018, 44, p. 3412–3416. https://doi.org/10.1016/j.ceramint.2017.11.135
• 38 K. Wang, M. Qiu, C. Jiao, J. Gu, D. Xie, C. Wang, et al. Study on defect-free debinding green body of ceramic formed by DLP technology, Ceram Int 2020, 46, p. 2438–2446. https://doi.org/10.1016/j.ceramint.2019.09.237
• 39 M.L. Griffith, J.W. Halloran, Freeform Fabrication of Ceramics via Stereolithography, J Am Ceram Soc 1996, 79, p. 2601–2608. https://doi.org/https://doi.org/10.1111/j.1151-2916.1996.tb09022.x
• 40 Z. Chen, Z. Li, J. Li, C. Liu, C. Lao, Y. Fu, et al. 3D printing of ceramics: A review, J Eur Ceram Soc 2019, 39, p. 661–687. https://doi.org/10.1016/j.jeurceramsoc.2018.11.013
• 41 S.A. Rasaki, D. Xiong, S. Xiong, F. Su, M. Idrees, Z. Chen, Photopolymerization- -based additive manufacturing of ceramics: A systematic review, J Adv Ceram 2021, 10, p. 442–471. https://doi.org/10.1007/s40145-021-0468-z
• 42 A. Więcław-Midor, J. Tańska, P. Falkowski, P. Wiecińska, Polimeryzacja indukowana fotochemicznie w przyrostowych metodach formowania elementów ceramicznych, Szkło i Ceramika 2023, str. 31-37
• 43 C. Qian, K. Hu, . Li, P. Li, Z. Lu, The effect of light scattering in stereolithography ceramic manufacturing, J Eur Ceram Soc 2021, 41, p. 7141–7154. https://doi.org/10.1016/j.jeurceramsoc.2021.07.017
• 44 D.A. Komissarenko, P.S. Sokolov, A.D. Evstigneeva, I.A. Shmeleva, A.E. Dosovitsky, Rheological and curing behavior of acrylate-based suspensions for the DLP 3D printing of complex zirconia parts, Materials (Basel) 2018, p. 11. https://doi.org/10.3390/ma11122350
• 45 R. Brucculeri, L. Airoldi, P. Baldini, B, Vigani, S. Rossi, S. Morganti, et al., Spark Plasma Sintering of Complex Metal and Ceramic Structures Produced by Material Extrusion, 3D Print Addit Manuf 2023. https://doi.org/10.1089/3dp.2022.0279
• 46 A.K. Hofer, A. Kocjan, R. Bermejo, High-strength lithography-based additive manufacturing of ceramic components with rapid sintering, Addit Manuf 2022, 59, p. 103141. https://doi.org/10.1016/j.addma.2022.103141
• 47 P. Cai, L. Guo, L. Liu, Q. Zhang, J. Li, Q. Lue, Rapid manufacturing of silica glass parts with complex structures through stereolithography and pressureless spark plasma sintering, Ceram Int 2022, 48, p. 55–63. https://doi.org/10.1016/j.ceramint.2021.08.345