Thermoplastic 3D Printing—An Additive Manufacturing Method for Producing Dense Ceramics

Abstract

In our new approach-thermoplastic 3D printing-a high-filled ceramic suspension based on thermoplastic binder systems is used to produce dense ceramic components by additive manufacturing. Alumina (67 vol%) and zirconia (45 vol%) suspensions were prepared by ball milling at a temperature of about 100°C to adjust a low viscosity. After the preparation the suspension solidified at cooling. For the sintered samples (alumina at 1600°C, zirconia at 1500°C), a density of about 99% and higher was obtained. FESEM studies of the samples' cross section showed a homogenous microstructure and a very good bond between the single printed layers.

Additive Technology: Update on Current Materials and Applications in Dentistry

“…Use of SLS technology to produce ceramics involves either ceramic powder or a pre‐sintered ceramic. To date, however, direct SLS of ceramic powder has only yielded porous structures difficult to post‐process to high density, so it has been mainly used to produce modified glass‐ceramics for fabrication of bioactive tissue scaffolds . However, SLS techniques on porcelain slurry have achieved a dense final ceramic structure .…”

Layered Manufacturing of Dental Ceramics: Fracture Mechanics, Microstructure, and Elemental Composition of Lithography‐Sintered Ceramic

“…A new production method is needed to build up ceramic restorations. Hence, layered manufacturing techniques that are used successfully for production of metal structures should be a good option for dental ceramic applications …”

Extrusion-based additive manufacturing of ZrO2 using photoinitiated polymerization

“…The most commonly employed techniques include i.e. Stereolithography (SLA) [15], Lithography-based Ceramic Manufacturing (LCM) [16], Freeze-Form Extrusion (FFE) [17], Selective Laser Sintering (SLS) [18,19], Selective Laser Melting (SLM) [20], Fused Deposition of Ceramics (FDC) [21], Robocasting [22] and Thermoplastic 3D-Printing (T3DP) [23].…”

“…Upon deposition, the thermoplastic material solidifies, trapping the ceramic particles. Thus, Scheithauer et al obtained a density of up to 99% after sintering [23].…”