Photopolymerization-based additive manufacturing of ceramics: A systematic review

Abstract

Conversion of inorganic-organic frameworks (ceramic precursors and ceramic-polymer mixtures) into solid mass ceramic structures based on photopolymerization process is currently receiving plentiful attention in the field of additive manufacturing (3D printing). Various techniques (e.g., stereolithography, digital light processing, and two-photon polymerization) that are compatible with this strategy have so far been widely investigated. This is due to their cost-viability, flexibility, and ability to design and manufacture complex geometric structures. Different platforms related to these techniques have been developed too, in order to meet up with modern technology demand. Most relevant to this review are the challenges faced by the researchers in using these 3D printing techniques for the fabrication of ceramic structures. These challenges often range from shape shrinkage, mass loss, poor densification, cracking, weak mechanical performance to undesirable surface roughness of the final ceramic structures. This is due to the brittle nature of ceramic materials. Based on the summary and discussion on the current progress of material-technique correlation available, here we show the significance of material composition and printing processes in addressing these challenges. The use of appropriate solid loading, solvent, and preceramic polymers in forming slurries is suggested as steps in the right direction. Techniques are indicated as another factor playing vital roles and their selection and development are suggested as plausible ways to remove these barriers.

3D/4D Printing of Polymers: Fused Deposition Modelling (FDM), Selective Laser Sintering (SLS), and Stereolithography (SLA)

“…A variety of AM methods are available to 3D print a wide range of materials including metals [ 20 , 21 , 22 , 23 ], polymers [ 24 , 25 , 26 , 27 , 28 , 29 ], polymer composites [ 30 , 31 , 32 , 33 ], ceramics [ 34 , 35 , 36 , 37 , 38 , 39 ], and cement [ 40 , 41 , 42 , 43 ]. The ASTM (ISO/ASTM 52900:2015) has classified the range of AM processes into seven general categories.…”

Toward High Resolution 3D Printing of Shape-Conformable Batteries via Vat Photopolymerization: Review and Perspective

“…This approach has been optimized over the years to obtain ceramics for all kinds of applications [57]. An example is the use of preceramic polymers such as polysiloxanes or polycarboxiloxanes, that upon thermal treatment above or at 1100ºC produces SiC, SiCN, or SiOC ceramics [58][59][60].…”

“…These examples, among others [63,64], are a testament of the potential of electroactive oxides to be obtained following this approach. Frequently encountered problems after sintering classical ceramic materials are non-homogeneous shrinkage, heavy mass loss, poor densification, cracking, weak mechanical performance, and undesirable surface roughness [57]. For battery materials, challenges are expected in every step of the manufacturing process.…”

Effects of Sintering Behaviors on Dimensional Accuracy, Surface Quality, and Mechanical Properties of Stereolithography-printed 3Y-ZrO2 Ceramics

“…Compared with traditional machining methods, additive manufacturing has recently provided a new resolution for these problems [8,9]. As reported, the 3D printing technologies applicable to ZrO2 ceramics mainly include stereolithography (SLA) [10], direct ink writing (DIW) [11], digital light processing (DLP) [12], fused deposition molding (FDM) [13], and selective laser sintering/melting (SLS/SLM) [14,15].…”