Bio‐Inspired Ceramic–Metal Composites Using Ceramic 3D Printing and Centrifugal Infiltration

Abstract

To address the strength–toughness dilemma, various techniques for the preparation of ceramic–metal composites have been proposed. Utilizing stereolithographic additive manufacturing and centrifugal infiltration, a method for the preparation of bio‐inspired ceramic–metal composites is proposed. The proposed method offers flexibility in the design of individual phases of ceramic–metal composites architecturally, with the benefits of scalability and individual phase dimensional control. The versatility of this approach is demonstrated by fabricating silica–aluminum composites with structures inspired by mineralized layers in bivalve mollusk shells, including both 2D prismatic and 3D interpenetrating composites. For composites in compression, the measured specific strength is as high as 169% than that of the base metal (monolithic 6061 aluminum alloy). The highest crack growth toughness of 12.89 MPa m1/2 is recorded. The crack growth sequence shows crack deflection at ceramic–metal interfaces. Based on the tomographic structural analysis of the ceramic parts, the porosity of the green and sintered parts are 9% and 15%, respectively. It is believed that the strength and fracture toughness of these ceramic–metal composites could be further improved if the mechanical properties of the ceramic components can be improved by reducing porosity and structural defects during printing and sintering steps.

Additive Manufacturing of Bioceramic Implants for Restoration Bone Engineering: Technologies, Advances, and Future Perspectives

“…Li et al 139 proposed a biomimetic structure based on pearl shells and prepared ceramic-metal biphasic materials using stereolithography and metal fusion infiltration to enhance the fracture toughness and strength of the block. This provided a novel direction for the design of bionic structures for implants.…”

Multifunctional nacre-like materials

“…The emergence of ceramic photopolymerization techniques provided opportunities to address this challenge by printing both the shape and arrangement of the building blocks simultaneously. 44 Thus, the shape of the building blocks is not restricted to platelets, and full control over how the blocks are arranged can be achieved. Building block shapes such as square, rectangular, circular, and hexagonal have been recently explored using a commercially available 3D printer and ceramic resin, followed by the ceramic sintering process (Fig.…”

“…4(c)). 44 The architecture was then put onto a spring-driven centrifugal casting machine, where the spring was tensioned. The aluminium alloy was then melted using a handheld torch and poured into the scaffolds.…”