Dense alumina and Ni-Zn-Cu ferrites, and porous hydroxyapatite (HAP) have been fabricated using a fused deposition modeling (FDM) type 3D printer, so-called "Additive Manufacturing (AM)". Green bodies of the former two were consisted of the laminated layer filaments from ceramics/resin = 60/40 vol% kneaded bodies to obtain dense ceramics. On the other hand, the latter was composed of 50/50 or 55/45 vol% filaments for porous scaffold. Binder-out process was performed in air with the selected temperature range/heating rate and final 673~723 K for 1.08~18.0 • 10 5 s, corresponding to each material. Hot Isostatic Pressed fine grained alumina after microwave sintering with an apparent relative density of 94%, substantially more than 98% by looking at the microstructure, revealed a bending strength of 562 MPa. Permeability µ of dense Ni-Zn-Cu ferrite sintered in air was nearly the same as that of conventional one; at low frequencies µ of "AM" ferrite surpassed the latter. Porous two kinds of HAP ceramics were fabricated from the different calcining temperatures 1223 and 1248 K, and biotested in terms of the cell culture at 310 K for 8.64 and 25.9 • 10 4 s. The cells on HAP produced from 1223 K calcined grew twofold in comparison with those of control glass.
KEY WORDSFDM, 3D printer, alumina, Ni-Zn-Cu ferrite, hydroxyapatite
Fused deposition modeling (FDM) with a 3D printer, one of so-called "Additive Manufacturing (AM)", is a promising advanced industrial production method. However, there are much difficulty in the fabrication of dense ceramics using a FDM-type 3D printer; i) preparation of "filament" used for supplying raw materials to the printer, ii) thermal management during AM to adjust both the viscosity and yield stress of melting filament appropriately, and iii) sintering densification of powder compacts. To meet these requirements, ceramics powders consisting of bimodal fine/coarse particles in zirconia-alumina system and unimodal hydroxyapatite powders were adopted for the starting raw materials. Homogenous filament with the compositions of (ZrO 2 -Al 2 O 3 )/binder = 65/35vol% were prepared by reducing the thickness of resin layer to 110~140 nm and extruded into the strand filaments with the diameter of 1.8-2.0 mm around 423 K. After AM under the viscosity γ and yields stress σ y , less than 1.60•10 2 Pa•s and 2.0 MPa, respectively, of kneaded body, and defatting at 773 K in air, the powder compacts were densified by microwave sintering at 1723 K for 6.0•10 2 s in N 2 . As-obtained material showed a high relative density more than 95.0%. In addition, capsule-free HIP treatment brought much densification by removing the closed pores inside materials.
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