Monitoring of critical processing steps during the production of high dense 3D alumina parts using Fused Filament Fabrication technology

Abstract

Among methods covered under the additive manufacturing family, the Fused Filament Fabrication (FFF) is considered one of the most accessible, variable, and cost-effective prototyping techniques for processing polymer and composite materials. In this paper, however, the FFF technique is used to fabricate highly dense alumina parts of different designs (cylinders, bars, and pillars) using a low-cost desktop 3D printer. To investigate the repeatability and reliability of filament-based 3D printing, micro-computed tomography (micro-CT) was applied to analyse and evaluate critical processing steps during the preparation of high dense alumina ceramics. Results of non-destructive testing showed that the 3D sample shape plays a significant role in defect-free printouts, and the printed errors and deviations increased in the direction from cylindrical to prismatic objects. Despite internal cracks, pores and cavities revealed by the micro-CT analysis, sintered objects achieved relative densities of up to 96%.