Printing of Zirconia Parts via Fused Filament Fabrication.

Dorit Nötzel,Ralf Eickhoff,Christoph Pfeifer,Thomas Hanemann

doi:10.3390/ma14195467

Dorit Nötzel, Ralf Eickhoff + Show 2 more

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https://doi.org/10.3390/ma14195467

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Abstract

In this work, a process chain for the fabrication of dense zirconia parts will be presented covering the individual steps feedstock compounding, 3D printing via Fused Filament Fabrication (FFF) and thermal postprocessing including debinding and sintering. A special focus was set on the comprehensive rheological characterization of the feedstock systems applying high-pressure capillary and oscillation rheometry. The latter allowed the representation of the flow situation especially in the nozzle of the print head with the occurring low-shear stress. Oscillation rheometry enabled the clarification of the surfactant’s concentration, here stearic acid, or more general, the feedstocks composition influence on the resulting feedstock flow behavior. Finally, dense ceramic parts (best values around 99 % of theory) were realized with structural details smaller than 100 µm.

Highlights

IntroductionIn addition to the different variants of vat photopolymerization, like stereolithography (SLA), material extrusion methods (MEX), especially Fused Filament Fabrication, are widely used for component fabrication beyond commercial material usage
With respect to the realization of dense zirconia parts applying Fused Filament Fabrication (FFF), a process chain was adapted from ceramic injection molding
The specific surface area is important for the calculation of the necessary surfactant amount

Summary

Introduction

In addition to the different variants of vat photopolymerization, like stereolithography (SLA), material extrusion methods (MEX), especially Fused Filament Fabrication, are widely used for component fabrication beyond commercial material usage. This can be attributed to the relatively simple printer setup and low printer costs and, in the case of the 3D printing of polymer-matrix composites, the exploitation of established techniques from polymer processing, like compounding and shaping. The highly filled polymer is used as a vehicle enabling a certain melt flow for shaping like in powder injection molding (PIM) By convention, in the latter case, the polymer-based composite is called feedstock

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