Additive manufacturing of zirconia parts by fused filament fabrication and solvent debinding: Selection of binder formulation

Cano, Santiago Cano; González-Gutiérrez, Joamín; Sapkota, Janak; Spoerk, Martin; Arbeiter, Florian; Schuschnigg, Stephan; Holzer, Clemens

doi:10.1016/j.addma.2019.01.001

Cited by 59 publications

(60 citation statements)

References 52 publications

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“…The evolving growth of scientific studies (displayed in purple in Figure ) on polystyrene (PS), poly(ether sulfone), poly(butylene terephthalate), and other polyesters, as well as poly(ε‐caprolactone) represent the expanding urge of widening the material portfolio. The fact that even niche materials, such as plant‐based polymers, biopolymers, silicone elastomers, recycled polymers, or highly filled polymers for the production of metals/ceramics, have been under investigation for the use in ME‐AM confirms the desired rapid growth in the process's material variety. Nevertheless, the usability of such novel materials for ME‐AM as an everyday usable and reliable material such as PLA or ABS will be determined in the future.…”

Section: Introductionmentioning

confidence: 99%

Material extrusion‐based additive manufacturing of polypropylene: A review on how to improve dimensional inaccuracy and warpage

Spoerk

Holzer

González-Gutiérrez

2019

J of Applied Polymer Sci

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201

172

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Material extrusion-based additive manufacturing (ME-AM) is an emerging processing technique that is characterized by the selective deposition of thermoplastic filaments in a layer-by-layer manner based on digital part models. Recently, it has attracted considerable attention, as this technique offers manifold benefits over conventional manufacturing technologies. However, to meet the challenges of complex industrial applications, certain shortcomings of ME-AM still need to be overcome. A case in point is the limited amount of semicrystalline thermoplastics, which are still not established as reliable, commercial filament materials. Particularly, polypropylene (PP) offers attractive properties that are unique among the ME-AM material portfolio. This review describes the current approaches of fabricating PP components by ME-AM. Both commercial and scientific strategies to make PP 3D-printable are elaborated and compared. As dimensional issues are especially problematic for PP, a comprehensive section of this review focuses on the strategies developed for mitigating warpage for PP parts fabricated by ME-AM.

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Section: Introductionmentioning

confidence: 99%

Material extrusion‐based additive manufacturing of polypropylene: A review on how to improve dimensional inaccuracy and warpage

Spoerk

Holzer

González-Gutiérrez

2019

J of Applied Polymer Sci

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201

172

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“…As previously mentioned, finding the right combination of polymers is not a simple task due to the contradictory requirements of FFF and, later on, during debinding. Possible binder compositions for sinterable FFF filaments were discussed previously [19,29].…”

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confidence: 99%

Optimization of the 3D Printing Parameters for Tensile Properties of Specimens Produced by Fused Filament Fabrication of 17-4PH Stainless Steel

et al. 2020

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Fused filament fabrication (FFF) combined with debinding and sintering could be an economical process for three-dimensional (3D) printing of metal parts. In this paper, compounding, filament making, and FFF processing of feedstock material with 55% vol. of 17-4PH stainless steel powder in a multicomponent binder system are presented. The experimental part of the paper encompasses central composite design for optimization of the most significant 3D printing parameters (extrusion temperature, flow rate multiplier, and layer thickness) to obtain maximum tensile strength of the 3D-printed specimens. Here, only green specimens were examined in order to be able to determine the optimal parameters for 3D printing. The results show that the factor with the biggest influence on the tensile properties was flow rate multiplier, followed by the layer thickness and finally the extrusion temperature. Maximizing all three parameters led to the highest tensile properties of the green parts.One of the most commonly used AM technologies for the production of metal parts is PBF. In PBF, a laser or electron beam selectively fuses metal powder or metal powder covered with a binding agent by scanning cross-sectional layers generated from a CAD file of the part on the surface of a powder bed. After one cross-section is scanned, the powder bed is lowered and a new layer of powder is added on top of the previous one; the process repeats until the part is finished [6]. One of the biggest disadvantages of PBF is that it relies on high-power lasers or high-energy electron beams, which can be very costly. In addition, the powder must be free-flowing and, therefore, it requires a specific powder distribution, which adds to the price of the material. Therefore, MEAM shows great promise as a cost-effective alternative since the shaping equipment is orders of magnitude cheaper than PBF [6], and powders with a great range of particle size distributions can be processed. In the most common type of MEAM, the building material is supplied in the form of spooled filaments and, therefore, is also known as fused filament fabrication (FFF). In most FFF machines, the filament is fed into a heating unit with a nozzle using counter-rotating rollers as a feeding system. The extrusion head is controlled to move in the XY plane, and, as it moves, material is extruded through the nozzle on a flat platform that moves in the Z-direction [5]. However, there are also MEAM systems, where the extrusion system is fixed and the printing platform moves in three axes [7], and systems where the printed head moves in three axes and the building platform is fixed [8].FFF was first developed for polymeric materials; however, for the fabrication of metal or ceramic parts, a filament made of a polymeric blend filled with a large portion of metal or ceramic particles, known as feedstock, is used. After shaping the filament into what is referred to as the green parts, the binder system is removed from the part by thermal, catalytic, or solvent extraction and then sintered to ob...

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“…The fabrication of ceramic or metallic parts by FFF has the major advantage that experience derived from powder injection molding (PIM) helps to develop highly filled feedstocks (ceramic: >45 vol.%, metal: >60 vol.% solid load) with a similar binder composition [ 23 , 24 ]. Considering only ceramics, up to now mostly sintered alumina or mullite [ 23 , 24 , 25 , 26 ], zirconia [ 27 , 28 , 29 ], or silicon nitride [ 30 ] parts have been realized, typical binder components are paraffin wax, (modified) polyolefines, or thermoplastic elastomers. Fatty-acid derivatives, like stearic acid, or commercial additives with proprietary composition, are widely established as surfactants or plasticizers [ 23 , 24 , 25 , 27 , 28 , 30 , 31 ].…”

Section: Introductionmentioning

confidence: 99%

“…Considering only ceramics, up to now mostly sintered alumina or mullite [ 23 , 24 , 25 , 26 ], zirconia [ 27 , 28 , 29 ], or silicon nitride [ 30 ] parts have been realized, typical binder components are paraffin wax, (modified) polyolefines, or thermoplastic elastomers. Fatty-acid derivatives, like stearic acid, or commercial additives with proprietary composition, are widely established as surfactants or plasticizers [ 23 , 24 , 25 , 27 , 28 , 30 , 31 ]. Like feedstocks in ceramic injection molding, two component binder mixtures are often applied, one low molecular mass material allows a low melt viscosity at moderate temperatures and one high molecular mass fraction (backbone polymer) delivers a certain mechanical stability at lower temperatures after shaping.…”

Section: Introductionmentioning

confidence: 99%

New Feedstock System for Fused Filament Fabrication of Sintered Alumina Parts

Nötzel

Hanemann

2020

Materials

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Only a few 3D-printing techniques are able to process ceramic materials and exploit successfully the capabilities of additive manufacturing of sintered ceramic parts. In this work, a new two component binder system, consisting of polyethyleneglycol and polyvinylbutyral, as well stearic acid as surfactant, was filled with submicron sized alumina up to 55 vol.% and used in fused filament fabrication (FFF) for the first time. The whole process chain, as established in powder injection molding of ceramic parts, starting with material selection, compounding, measurement of shear rate and temperature dependent flow behavior, filament fabrication, as well as FFF printing. A combination of solvent pre-debinding with thermal debinding and sintering at a reduced maximum temperature due to the submicron sized alumina and the related enhanced sinter activity, enabled the realization of alumina parts with complex shape and sinter densities around 98 % Th. Finally the overall shrinkage of the printed parts were compared with similar ones obtained by micro ceramic injection molding.

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Additive manufacturing of zirconia parts by fused filament fabrication and solvent debinding: Selection of binder formulation

Cited by 59 publications

References 52 publications

Material extrusion‐based additive manufacturing of polypropylene: A review on how to improve dimensional inaccuracy and warpage

Material extrusion‐based additive manufacturing of polypropylene: A review on how to improve dimensional inaccuracy and warpage

Optimization of the 3D Printing Parameters for Tensile Properties of Specimens Produced by Fused Filament Fabrication of 17-4PH Stainless Steel

New Feedstock System for Fused Filament Fabrication of Sintered Alumina Parts

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