Shell thickening for extrusion-based ceramics printing

Yu, Xiao; Zhou, Yu; Yan, Xin; Zhao, Haisen; Liu, Wenqiang; Jiang, Jingbo; Lü, Lin

doi:10.1016/j.cag.2021.04.031

Cited by 4 publications

(3 citation statements)

References 28 publications

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“…To quantify the distortion induced by each step of the post-processing cycle, the relative error with the previous operation is calculated as in equation (1) (Xing et al , 2021): where L i is the value of dimension L at the generic i -th step.…”

Section: Resultsmentioning

confidence: 99%

“…A different method for recycling scrap PA12 powders through clay material extrusion additive manufacturing (MEAM) has been recently proposed (Mele et al , 2021). The AM of clay is an increasingly important area of research due to the appealing properties of these materials (Xing et al , 2021; Wolf et al , 2022). Accordingly, numerous potential applications of 3D-printed clay parts have been shown in the literature (Biswas et al , 2020; Sangiorgio et al , 2022).…”

Section: Introductionmentioning

confidence: 99%

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Dimensional accuracy and impact resistance of 3D printed clay reinforced with scrap polymer powder

Mele

Campana

Pisaneschi

et al. 2023

RPJ

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Purpose The purpose of this paper is to give an insight into relevant aspects of 3D printing of clay paste enhanced with scrap polymer powder which have not been investigated by previous studies. Specifically, the geometrical features of the deposited lines, dimensional accuracy of benchmarks and mechanical properties of printed parts are investigated. Design/methodology/approach Firstly, the 3D printer is used to deposit lines of the paste under various combinations of material composition and process parameters. 3D scanning is used to measure their dimensional and geometrical errors. The results are elaborated through statistics to highlight the role of material and processing conditions. Then, four benchmark parts are printed using materials with different percentages of polymer powder. The parts are scanned after each step of the post-processing to quantify the effects of printing, drying and melting on dimensional accuracy. Finally, drop weight tests are carried out to investigate the impact resistance of specimens with different powder contents. Findings It is found that the quality of deposition varies with the printing speed, nozzle acceleration and material composition. Also, significant differences are observed at the ends of the lines. Materials with 10 Wt.% and 40 Wt.% of powder exhibit relevant shape variations due to the separation of phases. Accuracy analyses show significant deformations of parts at the green state due to material weight. This effect is more pronounced for higher powder contents. On the other hand, the polymer reduces shrinkage during drying. Furthermore, the impact test results showed that the polymer caused a large increase in impact resistance as compared to pure clay. Nonetheless, a decrease is observed for 40 Wt.% due to the higher amount of porosities. Research limitations/implications The results of this study advance the knowledge on the 3D printing of clay paste reinforced with a scrap polymer powder. This offers a new opportunity to reuse leftover powders from powder bed fusion processes. The findings presented here are expected to foster the adoption of this technique reducing the amount of waste powder disposed of by additive manufacturing companies. Originality/value This study offers some important insights into the relations between process conditions and the geometry of the deposited lines. This is of practical relevance to toolpath planning. The dimensional analyses allow for understanding the role of each post-processing step on the dimensional error. Also, the comparison with previous findings highlights the role of part dimensions. The present research explores, for the first time, the impact resistance of parts produced by this technology. The observed enhancement of this property with respect to pure clay may open new opportunities for the application of this manufacturing process.

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Dimensional accuracy and impact resistance of 3D printed clay reinforced with scrap polymer powder

Mele

Campana

Pisaneschi

et al. 2023

RPJ

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“…In Ref. [23], shell-like models were explored for extrusion-based ceramics printing. To conform to ceramic printing requirements, the authors calculated the moment equilibrium for each layer along the fabrication direction and enhanced the structural stability by local thickening.…”

Section: Thin Shell Manufacturingmentioning

confidence: 99%

Shell stand: Stable thin shell models for 3D fabrication

Xing,

Wang,

et al. 2024

Comp. Visual Media

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A thin shell model refers to a surface or structure, where the object’s thickness is considered negligible. In the context of 3D printing, thin shell models are characterized by having lightweight, hollow structures, and reduced material usage. Their versatility and visual appeal make them popular in various fields, such as cloth simulation, character skinning, and for thin-walled structures like leaves, paper, or metal sheets. Nevertheless, optimization of thin shell models without external support remains a challenge due to their minimal interior operational space. For the same reasons, hollowing methods are also unsuitable for this task. In fact, thin shell modulation methods are required to preserve the visual appearance of a two-sided surface which further constrain the problem space. In this paper, we introduce a new visual disparity metric tailored for shell models, integrating local details and global shape attributes in terms of visual perception. Our method modulates thin shell models using global deformations and local thickening while accounting for visual saliency, stability, and structural integrity. Thereby, thin shell models such as bas-reliefs, hollow shapes, and cloth can be stabilized to stand in arbitrary orientations, making them ideal for 3D printing.

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