Ceramic-Based 4D Components: Additive Manufacturing (AM) of Ceramic-Based Functionally Graded Materials (FGM) by Thermoplastic 3D Printing (T3DP)

Abstract

In our study, we investigated the additive manufacturing (AM) of ceramic-based functionally graded materials (FGM) by the direct AM technology thermoplastic 3D printing (T3DP). Zirconia components with varying microstructures were additively manufactured by using thermoplastic suspensions with different contents of pore-forming agents (PFA), which were co-sintered defect-free. Different materials were investigated concerning their suitability as PFA for the T3DP process. Diverse zirconia-based suspensions were prepared and used for the AM of single- and multi-material test components. All of the samples were sintered defect-free, and in the end, we could realize a brick wall-like component consisting of dense (<1% porosity) and porous (approx. 5% porosity) zirconia areas to combine different properties in one component. T3DP opens the door to the AM of further ceramic-based 4D components, such as multi-color, multi-material, or especially, multi-functional components.

Additive Manufacturing of Functionally Graded Ceramic Materials by Stereolithography

“…Different manufacturing approaches and materials lead to a variety of product properties, such as size, roughness, or mechanical properties. All additive manufacturing techniques can be classified into two groups: direct additive manufacturing technologies 5 , which are based on the selective deposition of the material (e.g., material jetting processes like Direct Inkjet Printing or Thermoplastic 3-D Printing [T3DP]) 7,8,9,10 , and indirect additive manufacturing technologies, which are based on the selective consolidation of the material which is deposited on the whole layer (e.g., ceramic stereolithography [SLA]).…”

Fused Filament Fabrication (FFF) of Metal-Ceramic Components

“…The AM of multi-material or multi-functional components combines the benefits of AM and functionally graded materials (FGM) 13 into ceramicbased 4D-components 14 . Material hybrids allow property combinations such as electrically conductive/insulating, magnetic/non-magnetic, ductile/hard or different colorations.…”

“…Along with lithography-based ceramic manufacturing (LCM) 7,8,9,10,11,16,17 , fused filament fabrication (FFF) and thermoplastic 3D-printing (T3DP) 12,14,18 are being developed. FFF and T3DP are more suitable for the AM of multi-material components than LCM because of the selective deposition and solidification of the certain material instead of the pure selective solidification of material deposited all over the entire layer 14 .…”

Multi-material Ceramic-Based Components &#8211; Additive Manufacturing of Black-and-white Zirconia Components by Thermoplastic 3D-Printing (CerAM - T3DP)

“…Ceramic-based FGM with a graded porosity like dense and porous zirconia combine very good mechanical properties in the dense areas with a high active surface of the porous areas. Such like components can be additively manufactured by CerAM -T3DP 18 .…”

“…CerAM -T3DP is based on the selective deposition of single droplets of particle filled thermoplastic suspensions. By utilizing multiple dosing systems, different thermoplastic suspensions can be deposited beside each other layer by layer to produce bulk material as well as property gradients within the additively manufactured green components 18 . Unlike indirect AM processes, in which previously deposited materials solidify selectively over the entire layer, the CerAM -T3DP process does not require the additional effort of removing any non-solidified material prior to the deposition of the next material, making it more suitable for the AM of multi-material components.Although utilizing the CerAM -T3DP process allows the AM of FGM and the realization of ceramic-based components with unprecedented properties, there are challenges to overcome regarding the necessary thermal treatment after the AM process, in order to obtain a multimaterial composite.…”