Stereolithographic 3D Printing of Ceramics: Challenges and Opportunities for Structural Integrity

Staudacher, Maximilian; Hofer, Anna-Katherina; Schlacher, Josef; Bermejo, Raúl

doi:10.1002/adem.202200520

Cited by 25 publications

(7 citation statements)

References 53 publications

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“…SLA is used in both the ceramic [46] and polymeric materials fields [47] for its ability to produce highly accurate and detailed parts with very smooth surface finishes [48,49]. One potential drawback of SLA is that it can be relatively slow.…”

Section: Stereolithographic 3d Printing (Sla)mentioning

confidence: 99%

3D Printing of Layered Structures of Metal-Ionic Polymers: Recent Progress, Challenges and Opportunities

Martinelli,

Nitti,

et al. 2023

Materials

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Layered Structures of Metal Ionic Polymers, or Ionic Polymer-Metal Composites (IPMCs) are formed by a membrane of an ionic electroactive materials flanked by two metal electrodes on both surfaces; they are devices able to change their shape upon application of an electrical external stimulus. This class of materials is used in various fields such as biomedicine, soft robotics, and sensor technology because of their favorable properties (light weight, biocompatibility, fast response to stimulus and good flexibility). With additive manufacturing, actuators can be customized and tailored to specific applications, allowing for the optimization of performance, size, and weight, thus reducing costs and time of fabrication and enhancing functionality and efficiency in various applications. In this review, we present an overview of the newest trend in using different 3D printing techniques to produce electrically responsive IPMC devices.

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Section: Stereolithographic 3d Printing (Sla)mentioning

confidence: 99%

3D Printing of Layered Structures of Metal-Ionic Polymers: Recent Progress, Challenges and Opportunities

Martinelli,

Nitti,

et al. 2023

Materials

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“…Among the available additive manufacturing (AM) methodologies for forming ceramic materials, lithographybased ceramic manufacturing (LCM) has become a preferred AM method because of its advantageous capabilities in on-demand manufacturing, part customization, and prototyping. [1][2][3] LCM is a layer-based, vat photopolymerization technique that polymerizes a photocurable ceramic suspension. 4 Many initial studies indicate favorable outcomes for the flexural strength properties of LCM alumina.…”

Section: Introductionmentioning

confidence: 99%

Linking flexural strength and strength‐limiting flaws in additively manufactured alumina with print parameter variations

Boardman,

Packard

2023

J Am Ceram Soc.

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Advancing the adoption of lithography‐based ceramic manufacturing (LCM) for structural applications requires understanding how processing parameters impact the printed material's flaw population and failure behavior. Exploratory studies on LCM alumina have mixed results regarding print parameter influence on strength and past fractography is insufficiently complete to guide process engineering for better performance. We perform four‐point flexural strength characterization and comprehensive fractography of LCM alumina to evaluate the impact of processing parameters including orientation, layer height, and curing energy on strength‐limiting defects. Characteristic strengths for fully dense, high‐purity LCM alumina are near or above conventionally processed alumina within the manufacturable range of print parameters studied in this work. Conversely, the Weibull modulus varies greatly (m = 3.8–19.5) depending on print parameters. The dominant strength‐controlling defects all have a printing‐based origin, but vary between delamination, surface texture, and bubbles depending on print orientation. Lowest performance results from alignment of the print axis along the bar length, yielding a low Weibull modulus associated with weak delamination flaws that are not appreciably improved by varying print layer height or curing energy.

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“…In order to assess and analyze recent review articles in this area, a Scopus search was conducted in April 2023 for the specific time frame of 2018–2023. This search resulted in 165 review articles on ceramic additive manufacturing or some subset of that topic 1,3–166 . Figure 1 shows a graphical representation of the number of review articles separated into five focus areas.…”

Section: Introductionmentioning

confidence: 99%

Future directions in ceramic additive manufacturing: Fiber reinforcements and artificial intelligence

Rueschhoff,

Baldwin,

Hardin

et al. 2023

J Am Ceram Soc.

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Research in the field of ceramic additive manufacturing (AM) has been rapidly accelerating, resulting in hundreds of publications and review articles in recent years. While strides have been made in forming near‐net and complex‐shaped ceramic components, challenges remain that inhibit more widespread implementation. In this perspective, we provide a meta‐analysis of recent review articles and highlight a deficiency in two areas of promising future directions to address remaining challenges. The first is incorporation of fiber reinforcements in printed parts to overcome the challenges of poor mechanical performance of monolithic ceramics. Recent work in the area has shown promise incorporating discrete fiber reinforcements as an easier use case given existing equipment limitations, but continuous fibers are needed to reach full toughness potential. Here, we overview some options and future directions bases on success in polymer composites. Second, artificial intelligence (AI) approaches, including machine learning (ML), are suggested in order to accelerate feedstock development and process optimization. While there has been very limited work to date in utilizing AI/ML techniques for ceramic AM, again inspiration and lessons learned are drawn from the polymer AM community.

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Stereolithographic 3D Printing of Ceramics: Challenges and Opportunities for Structural Integrity

Cited by 25 publications

References 53 publications

3D Printing of Layered Structures of Metal-Ionic Polymers: Recent Progress, Challenges and Opportunities

3D Printing of Layered Structures of Metal-Ionic Polymers: Recent Progress, Challenges and Opportunities

Linking flexural strength and strength‐limiting flaws in additively manufactured alumina with print parameter variations

Future directions in ceramic additive manufacturing: Fiber reinforcements and artificial intelligence

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