Direct Ink Writing of Three‐Dimensional Ceramic Structures

Abstract

The ability to pattern ceramic materials in three dimensions (3D) is critical for structural, functional, and biomedical applications. One facile approach is direct ink writing (DIW), in which 3D structures are built layer-by-layer through the deposition of colloidal-or polymer-based inks. This approach allows one to design and rapidly fabricate ceramic materials in complex 3D shapes without the need for expensive tooling, dies, or lithographic masks. In this feature article, we present both dropletand filament-based DIW techniques. We focus on the various ink designs and their corresponding rheological behavior, ink deposition mechanics, potential shapes and the toolpaths required, and representative examples of 3D ceramic structures assembled by each technique. The opportunities and challenges associated with DIW are also highlighted.

Three-dimensional printed yttria-stabilized zirconia self-supported electrolytes for solid oxide fuel cell applications

“…However, whilst 3D printing of polymeric and metallic objects is being used, even industrially, for already a decade [7]- [10], the fabrication of 3D printed ceramic parts is still mainly under research level development [11]. Among other, 3D printing technologies including selective laser sintering (SLS) [13], direct [14] and indirect [15] inkjet printing (DIP and IIP) and stereolithography (SLA) [16] have been used so far for the fabrication of functional ceramic devices. In particular, the reader is referred to the review by Ruiz-Morales et al [12] on the most recent developments of 3D printing of ceramics in the field of energy and, more specifically, for Solid Oxide Fuel Cells applications.…”

Robocasting of biomimetic hydroxyapatite scaffolds using self-setting inks

“…2,3 In the specic case of ceramic scaffolds, a sintering step is applied aer printing the green body. High temperature sintered calcium phosphates, such as hydroxyapatite (HA), beta tricalcium phosphate (b-TCP) or even bioglass, have been employed to develop robocasted scaffolds for bone tissue engineering.…”

Rheological behavior of PMN gels for solid freeform fabrication

“…It is a solid free form fabrication method that utilizes colloidal systems of low organic content [21][22][23]. Previously, Lewis and co-workers conducted intensive research on the robocasting of alumina [24], barium titanate [25] and lead zirconate titanate [26][27][28] powders and produced different geometries to be used in different applications [21].…”

“…This can be achieved by manipulating the geometry of simple shape actuators into more complex geometries [13,14]. Direct write technologies are able to produce 2D or 3D periodic structures to use in these application areas [15][16][17][18][19][20][21].…”

“…Furthermore, colloidal inks developed for the robotic deposition must able to flow through the nozzle and then set immediately to keep the shape retention. In other words, the particle network must be able to resist stresses arising from capillary tension [6,21,22]. Therefore, preparation of colloidal inks that are capable of flowing through the nozzles of varying size and then setting immediately to facilitate shape retention of the deposited features is crucial in direct writing techniques [4,23].…”