Multiphysics and geometry-based modeling of incorporating mass transport networks in ceramic green bodies to improve thermal debinding

Abstract

Binder-based ceramic manufacturing is an integral technique for fabricating intricate ceramic structures. These structures can be formed (e.g., through injection molding) or additively manufactured (e.g., extrusion-based 3D printing). However, the debinding process poses a significant challenge, due to the time for binder removal increasing with the square of the part thickness, and excessive pressure buildup that can lead to cracks in the part. In this study, we explore the use of mass transport networks to accelerate debinding and reduce pressure buildup. We employ two modeling approaches: multiphysics and geometry-based modeling. The results indicate that the addition of appropriately selected mass transport networks can reduce the maximum pressure to below the critical pressure. The binder diffusion rate increases due to the network, enabling faster debinding times. This innovative approach enables faster processing and successful fabrication of larger structures, offering significant energy and cost savings while expanding design possibilities. Network design can be validated and optimized through modeling and incorporated via additive manufacturing.