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Wollastonite (CaSiO 3 ) – diopside (CaMgSi 2 O 6 ) glass-ceramic scaffolds have been successfully fabricated using two different additive manufacturing techniques: powder-based 3D printing (3DP) and digital light processing (DLP), coupled with the sinter-crystallization of glass powders with two different compositions. The adopted manufacturing process depended on the balance between viscous flow sintering and crystallization of the glass particles, in turn in fluenced by the powder size and the sensitivity of CaO – MgO – SiO 2 glasses to surface nucleation. 3DP used coarser glass powders and was more appropriate for low temperature firing (800 – 900 °C), leading to samples with limited crystallization. On the contrary, DLP used finer glass powders, leading to highly crystallized glass-ceramic samples. Despite the differences in manufacturing technology and crystallization, all samples featured very good strength-to-density ratios, which bene fit theiruse for bone tissue engineering applications. The bioactivity of 3D-printed glass-ceramics after immersion in simulated body fluid and the similarities, in terms of ionic releases and hydroxyapatite formation with already validated bioactive glass-ceramics, were preliminarily assessed.
Capsule summary
THE MATERIALS
Manufacturers can use preceramic polymers to produce ceramic components in a range of compositions using a variety of additive manufacturing technologies. Preceramic polymers even can overcome some of the problems that are intrinsic to additive manufacturing in general.
THE APPLICATION
Modifying the composition, molecular architecture, and molecular weight of preceramic polymers allows adaptation of these materials to specific processing requirements of individual additive manufacturing technologies.
THE OPPORTUNITY
Further development of new additive manufacturing technologies, in addition to improvement of existing technologies, will enable manufacturing of advanced ceramic components with enhanced mechanical characteristics and new functional properties.
The round robin test investigated the reliability users can expect for AlSi10Mg additive manufactured specimens by laser powder bed fusion through examining powder quality, process parameter, microstructure defects, strength and fatigue. Besides for one outlier, expected static material properties could be found. Optical microstructure inspection was beneficial to determine true porosity and porosity types to explain the occurring scatter in properties. Fractographic analyses reveal that the fatigue crack propagation starts at the rough as-built surface for all specimens. Statistical analysis of the scatter in fatigue using statistical derived safety factors concludes that at a stress of 36.87 MPa the fatigue limit of 107 cycles could be reached for all specimen with a survival probability of 99.999 %.
When it comes to higher accuracies, new technologies and real applications in additive manufacturing, there is one topic which cannot be avoided: The material response on the chosen processing parameters and its agreement and correspondence with literature data of the wrought material grade counterpart. In industrial Additive Manufacturing (AM) standards in terms of printing parameters, protection gas atmospheres or powder handling instructions are not obligatory. Therefore, the question must be answered whether the AM process is reproducible and reliable over different printing companies. This was the motivation to realize a round robin test between 8 European printing companies and academic partners. The consortium had printed and tested fatigue and tensile testing bars under plant-specific conditions. A commonly used cast aluminum alloy, AlSi10Mg, was chosen as test material for the PBF-LB/M process. Differences of the results between the partners and the scatter itself were discussed in detail.
When it comes to higher accuracies, new technologies and real applications in additive manufacturing, there is one topic which cannot be avoided: The material response on the chosen processing parameters and its agreement and correspondence with literature data of the wrought material grade counterpart. In industrial Additive Manufacturing (AM) standards in terms of printing parameters, protection gas atmospheres or powder handling instructions are not obligatory. Therefore, the question must be answered whether the AM process is reproducible and reliable over different printing companies. This was the motivation to realize a round robin test between 8 European printing companies and academic partners. The consortium had printed and tested fatigue and tensile testing bars under plant-specific conditions. A commonly used cast aluminum alloy, AlSi10Mg, was chosen as test material for the PBF-LB/M process. Differences of the results between the partners and the scatter itself were discussed in detail.