5 Werkstofftechnik
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Organisationseinheit der BAM
- 5 Werkstofftechnik (46)
- 5.4 Keramische Prozesstechnik und Biowerkstoffe (46)
- 8 Zerstörungsfreie Prüfung (4)
- 8.5 Mikro-ZfP (4)
- 5.6 Glas (3)
- 4 Material und Umwelt (2)
- 5.1 Materialographie, Fraktographie und Alterung technischer Werkstoffe (2)
- 9 Komponentensicherheit (2)
- 9.3 Schweißtechnische Fertigungsverfahren (2)
- 4.0 Abteilungsleitung und andere (1)
The Layerwise Slurry Deposition is a technology for the deposition of highly packed powder layers. A powder bed is achieved by depositing and drying layers of a ceramic suspension by means of a doctor blade. This deposition technique was combined with the binder jetting technology to develop a novel Additive Manufacturing technology, named LSD-print. The LSD-print was applied to a porcelain ceramic. It is shown that it was possible to produce parts with high definition, good surface finish and at the same time having physical and mechanical properties close to those of traditionally processed porcelain, e.g. by slip casting.
This technology shows high future potential for being integrated alongside traditional production of porce-lain, as it is easily scalable to large areas while maintaining a good definition. Both the Layerwise Slurry Deposition method and the binder jetting technologies are readily scalable to areas as large as > 1 m2.
A shape evolution approach based on the thermally activated self-organization of 3D printed parts into minimal surface area structures is presented. With this strategy, the present communication opposes currently established additive manufacturing strategies aiming to stipulate each individual volumetric element (voxel) of a part. Instead, a 3D structure is roughly defined in a 3D printing process, with all its advantages, and an externally triggered self-organization allows the formation of structural elements with a definition greatly exceeding the volumetric resolution of the printing process. For enabling the self-organization of printed objects by viscous flow of material, functionally graded structures are printed as rigid frame and melting filler. This approach uniquely combines the freedom in design, provided by 3D printing, with the mathematical formulation of minimal surface structures and the knowledge of the physical potentials governing self-organization, to overcome the paradigm which strictly orrelates the geometrical definition of 3D printed parts to the volumetric resolution of the printing process. Moreover, a transient liquid phase allows local programming of functionalities, such as the alignment of functional particles, by means of electric or magnetic fields.
Silicate bioceramics possess an excellent bioactivity; however, shaping them into complex geometries is still challenging. Therefore, this paper aims to present a new strategy for the shaping of a bioglass-ceramic with controlled geometry and properties starting from a glass powder combined with a preceramic polymer, i.e. a silicon resin, and reactive fillers. The powder-based three-dimensional (3D)-printing of wollastonite (CaSiO3)-based silicate bioceramic parts was demonstrated in this work. The resin plays a dual role, as it not only acts as a non-sacrificial binder for the filler powders in the printing process but it also reacts with the fillers to generate the desired bioceramic phases. The mechanical and physical properties, i.e. ball-on-three-balls test, density, porosity and morphology, were evaluated in 3D-printed discs. These samples possessed a total porosity around 64 vol% and a biaxial flexural strength around 6 MPa. The raw materials used in this work also enabled the 3D-printing of scaffolds possessing a designed multi-scale porosity, suitable bioceramic phase assemblage and a compressive strength of 1 MPa (for cylindrical scaffolds with total porosity ~80 vol%). Solubility in TRIS/HCl and in vitro assays, i.e. viability, cytotoxicity and apoptosis assays, were also performed. In vitro tests indicated good cell viability and no cytotoxicity effect on the cells.
Additive manufacturing of alkali-activated materials currently attracts a lot of attention, because of the possibility to produce customized high-performance elements for a range of applications, potentially being more resource-efficient than conventionally produced parts. Here, we describe a new additive manufacturing process for alkali-activated materials that is based on selective laser-heating of lithium aluminate/microsilica slurries. The new process-material combination allows to manufacture elements with complex geometries at high building rates and high accuracy. The process is versatile and transferrable to structures of sizes differing by orders of magnitude. The mechanical strength of the obtained materials was in the range of values reported for conventional metakaolin-based geopolymers, and superior to what has been hitherto reported for alkali-activated materials produced by additive manufacturing. This mechanical performance was obtained despite the fact that the degree of reaction of the lithium aluminate and the microsilica was low, suggesting that significant reactions took place only at the surface of the microsilica particles.
Adapting trabecular structures for 3D printing: an image processing approach based on μCT data
(2017)
Materials with a trabecular structure notably Combine advantages such as lightweight, reasonable strength, and permeability for fl uids. This combination of advantages is especially interesting for tissue engineering in trauma surgery and orthopedics. Bone-substituting scaffolds for instance are designed with a trabecular structure in order to allow cell migration for bone ingrowth and vascularization. An emerging and recently very popular technology to produce such complex, porous structures is 3D printing. However, several technological aspects regarding the scaffold architecture, the printable resolution, and the feature size have to be considered when fabricating scaffolds for bone tissue replacement and regeneration. Here, we present a strategy to assess and prepare realistic trabecular structures for 3D printing using image analysis with the aim of preserving the structural elements. We discuss critical conditions of the printing system and present a 3-stage approach to adapt a trabecular structure from μ CT data while incorporating knowledge about the printing system. In the first stage, an image-based extraction of solid and void structures is performed, which results in voxel- and graph-based representations of the extracted structures. These representations not only allow us to quantify geometrical properties such as pore size or strut geometry and length. But, since the graph represents the geometry and the topology of the initial structure, it can be used in the second stage to modify and adjust feature size, volume and sample size in an easy and consistent way. In the final reconstruction stage, the graph is then converted into a voxel representation preserving the topology of the initial structure. This stage generates a model with respect to the printing conditions to ensure a stable and controlled voxel placement during the printing process.
Additive manufacturing (AM) is a technology which has the potential not only to change the way of conventional industrial manufacturing processes, adding material instead of subtracting, but also to create entirely new production and business strategies. Since about three decades, AM technologies have been used to fabricate prototypes or models mostly from polymeric or metallic materials. Recently, products have been introduced into the market that cannot be produced in another way than additively. Ceramic materials are, however, not easy to process by AM technologies, as their processing requirements (in terms of feedstock and/or sintering) are very challenging. On the other hand, it can be expected that AM technologies, once successful, will have an extraordinary impact on the industrial production of ceramic components and, moreover, will open for ceramics new uses and new markets.
Additive manufacturing of SiSiC by layerwise slurry deposition and binder jetting (LSD-print)
(2019)
The current work presents for the first time results on the Additive Manufacturing of SiSiC complex parts based on the Layerwise Slurry Deposition (LSD) process. This technology allows to deposit highly packed powder layers by spreading a ceramic slurry and drying. The capillary forces acting during the process are responsible for the dense powder packing and the good joining between layers. The LSD process can be combined with binder jetting to print 2D cross-sections of an object in each successive layer, thus forming a 3D part. This process is named LSD-print.
By LSD-print and silicon infiltration, SiSiC parts with complex geometries and features down to 1mm and an aspect ratio up to 4:1 could be demonstrated.
The density and morphology were investigated for a large number of samples. Furthermore, the density and the mechanical properties, measured by ball-on-three-balls method, were in all three building directions close to isostatic pressed references.
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.