Development of a binder formulation for fused deposition of ceramics

Abstract

A new binder formulation has been developed for Fused Deposition of Ceramics (FDC) which consists of commercially-available polymer constituents.. This formulation was used. in conjunction with lead zirconate titanate (PZT) and hydroxyapatite (HAp) powders. Adsorption studies were performed to test the effectiveness of several carboxylic acids and alcohols on the dispersion of these powders in the binder system. In both cases, it was found that stearic acid was most effective as a dispersant for the ceramic powder / thermoplastic system. After a suitable dispersant was chosen, ceramic powders were compounded with the binder formulation to yield 55 vol.% ceramic-loaded materials. The resultant compound was• used to make filament suitable for use in a modified StratasysTM 3D-Modeler. The filament was well suited for FDC usage, and the parts made using FDC contained no detectable filament-related defects.

Additive Manufacturing of Ceramic‐Based Materials

“…[148] The process is thus similar to the one applied when manufacturing a feedstock for injection molding. When homogeneity is achieved, the feedstock is extruded to form a filament which fits into the liquefier of the FDM machine.…”

“…During sintering, EFF workpieces experience anisotropic shrinkage. [127,154,161] [123,124,133,142,144,146,148,150] …”

Development and Electromechanical Properties of Multimaterial Piezoelectric and Electrostrictive PMN-PT Monomorph Actuators

“…The solids content of the two separate filament feedstock were 57 and 54.5% by volume for 0.65PMN-0.35PT and 0.9PMN-0.1PT, respectively. Further details of filament feedstock preparation can be found in refernece [9,10].…”

“…The ceramic powders (TRS Ceramics, PA, USA) were of ∼2 to 3 µm in average particle size, and were used to synthesize filament feedstock to be stacked layer-bylayer for warm pressing. The processing steps appertaining to preparation of filament feedstock included coating of the powders with stearic acid surfactant, mixing the powder with a proprietary binder, and extrusion of the powder-binder mixtures by employing a single screw extruder [9]. The solids content of the two separate filament feedstock were 57 and 54.5% by volume for 0.65PMN-0.35PT and 0.9PMN-0.1PT, respectively.…”

Feasibility of Fused Deposition of Ceramics with Zirconia and Acrylic Binder

“…Argarwala, FDC experiments have been performed using a broad range of ceramics including Si3N4, SiO2, Al2O3, PZT, SS, WC-Co and a thermoplastic binder series developed by Rutgers called the RU binder series (1996,1995,1996). Also from Rutgers, McNulty, Mohammadi, Bandyopadhyay, Shanefield, Danforth & Safari (1998) Onagoruwa (2006) was FDC using Al2O3 and fused silica with polypropylene-based thermoplastic binder to create metal-ceramic composite parts with increased strength. These main experiments are the basis for this thesis and will be referred to throughout the literature review and following sections, in which they will be spoken about in more detail.…”