Abstract
The fused filament fabrication (FFF) of ceramics enables the additive manufacturing of components with complex geometries for many applications like tooling or prototyping. Nevertheless, due to the many factors involved in the process, it is difficult to separate the effect of the different parameters on the final properties of the FFF parts, which hinders the expansion of the technology. In this paper, the effect of the fill pattern used during FFF on the defects and the mechanical properties of zirconia components is evaluated. The zirconia-filled filaments were produced from scratch, characterized by different methods and used in the FFF of bending bars with infill orientations of 0°, ±45° and 90° with respect to the longest dimension of the specimens. Three-point bending tests were conducted on the specimens with the side in contact with the build platform under tensile loads. Next, the defects were identified with cuts in different sections. During the shaping by FFF, pores appeared inside the extruded roads due to binder degradation and or moisture evaporation. The changes in the fill pattern resulted in different types of porosity and defects in the first layer, with the latter leading to earlier fracture of the components. Due to these variations, the specimens with the 0° infill orientation had the lowest porosity and the highest bending strength, followed by the specimens with ±45° infill orientation and finally by those with 90° infill orientation.
Highlights
Thanks to the considerable efforts and interest of the industry and research institutions, the ceramic additive manufacturing has experienced considerable development and growth that is forecasted to increase in the years [1]
The fused filament fabrication (FFF) of ceramics, known as Fused Deposition of Ceramics (FDC) [8,9,10], is a material extrusion (MEX) process based on the selective extrusion through a nozzle of feedstock in the shape of filament
The influence of the infill orientation on the properties of zirconia parts produced by FFF was evaluated
Summary
Thanks to the considerable efforts and interest of the industry and research institutions, the ceramic additive manufacturing has experienced considerable development and growth that is forecasted to increase in the years [1]. The fused filament fabrication (FFF) of ceramics, known as Fused Deposition of Ceramics (FDC) [8,9,10], is a MEX process based on the selective extrusion through a nozzle of feedstock in the shape of filament. The parts are sintered to obtain nearly dense components Some advantages of this technology include the simplicity and the low cost of the equipment required to shape the parts [20], the possibility to produce lightweight structures with closed geometry [19,20,21], the possibility to combine this technology with a well-established process like ceramic injection molding [22], and the ability to combine various materials in one part by the use of various nozzles [23,24,25]. The roughness in FFF parts and the minimum dimensions achievable are limited by the diameter of the nozzle [29,30]
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