Powder Loading Research Articles

3D printing of metal parts using a highly-filled thermoplastic filament

Purpose This study aims to develop a highly loaded filament with spherical metallic particles for fused filament fabrication (FFF) technology. The research focuses on optimizing powder loading, printing parameters and final processes, including debinding and sintering, to produce successful metal parts. Design/methodology/approach The optimal powder loading was identified by measuring mixing torque and viscosity at various temperatures. The filament was extruded, and printing parameters − particularly printing speed to ensure proper material flow − were optimized. Different filling patterns were also examined. After printing, the polymeric binder was removed and the parts were sintered to form the final metal components. Findings The optimal powder loading was determined to be 55 vol.%. The best surface quality was achieved with an optimized printing speed of 5 mm/s. Parts printed with various infill patterns were studied for differences in open, closed and total porosity, showing a strong link between porosity and infill pattern. Originality/value This comprehensive study provides new insights into manufacturing metal parts using FFF technology. It fills a gap in the literature regarding feedstock viscosity and shear rate in highly loaded metal filaments during FFF. Additionally, it uniquely examines the open, closed and total porosity of metal parts printed with different infill patterns.

Experimental investigation of material extrusion additive manufacturing of copper with high powder loading rate

Beam-based additive manufacturing has challenges in fabricating pure copper due to high reflectivity. Material extrusion additive manufacturing (MEAM) avoids these issues with low costs, making it suitable to fabricate complex structures in pure copper. In this work, the effects of several printing parameters on the geometry of the samples are studied from single line, thin wall to cube using homemade copper feedstocks with high powder loading rate (65 vol%). The results show that the single line is most affected by layer thickness, while the thin wall has stricter requirements for printing temperature and printing speed. The geometric accuracy of the cube demonstrates large parametric tolerance due to the overlap and support between the lines. Central composite face-centered (CCF) design and central composite design (CCD) are used to analyze and optimize process parameters for densification. The measured porosity at the optimized printing (printing temperature = 177 °C, air gap = −0.05 mm, layer thickness = 0.3 mm) and sintering parameters (sintering temperature = 1045 °C, holding time = 4 h) is in good agreement with the predicted values. Air gap and sintering temperature have the greatest influence on the porosity, and other parameters within a certain range of on-demand adjustments do not have a significant effect. The ultimate tensile strength and elongation of the sintered samples under the optimal parameters are 153.9 ± 6.1 MPa and 31.36 ± 3.24%, respectively. No printing defects are found at the fracture and the elongation is good, showing the effectiveness of the parameter optimization.

Highly‐Sensitive and High Operating Range Fully‐Printed Humidity Sensors Based on BiFeO3/BiOCl Heterojunctions

AbstractFully‐printed humidity sensors based on BiFeO3/BiOCl heterojunctions fabricated using a two‐step process with serigraphic printing are reported. Most importantly, this unique sensor architecture provides a broader relative humidity sensing range compared to pristine BFO sensors due to a synergistic effect between dense networks of BiOCl nanosheets synthetized atop BFO powders. With surface‐to‐weight ratios reaching 7.75 m2 g−1, these heterostructures increase the sensitivity and operating range of BFO‐based humidity sensors. While previously reported BFO humidity sensors only detect relative humidities above 30%, The BFO/BiOCl heterojunctions can measure relative humidities as low as 15% due to their increased surface area. Optimal growth and packing of the BiOCl nanosheet/BFO powder heterostructure are achieved by tuning the loading of the BFO powder and simultaneously forming the BiOCl sheets by chemical etching and annealing of the BFO powder. Excellent performance of optimized sensors including tracking and monitoring different types of breathing are demonstrated while mounted on an oxygen mask.

Powder Loading Effects on the Physicochemical and Mechanical Properties of 3D Printed Poly Lactic Acid/Hydroxyapatite Biocomposites.

This study presents the physicochemical and mechanical behavior of incorporating hydroxyapatite (HAp) with polylactic acid (PLA) matrix in 3D printed PLA/HAp composite materials. Effects of powder loading to the composition, crystallinity, morphology, and mechanical properties were observed. HAp was synthesized from locally sourced nanoprecipitated calcium carbonate and served as the filler for the PLA matrix. The 0, 5, 10, and 15 wt. % HAp biocomposite filaments were formed using a twin-screw extruder. The resulting filaments were 3D printed in an Ultimaker S5 machine utilizing a fused deposition modeling technology. Successful incorporation of HAp and PLA was observed using infrared spectroscopy and X-ray diffraction (XRD). The mechanical properties of pure PLA had improved on the incorporation of 15% HAp; from 32.7 to 47.3 MPa in terms of tensile strength; and 2.3 to 3.5 GPa for stiffness. Moreover, the preliminary in vitro bioactivity test of the 3D printed PLA/HAp biocomposite samples in simulated body fluid (SBF) indicated varying weight gains and the presence of apatite species’ XRD peaks. The HAp particles embedded in the PLA matrix acted as nucleation sites for the deposition of salts and apatite species from the SBF solution.

Complex-shaped titanium components fabricated via metal injection molding using hydride-dehydride titanium powder

Metal injection molding (MIM) is a net-shape manufacturing method that lessens the costs of production and increases the affordability of titanium goods. A range of CP-Ti specimens was prepared to confirm the primary manufacturing parameters for titanium metal injection molding utilizing affordable hydride-dehydride (HDH) powders. Mixture of powder and polyformaldehyde-based binder was injection molded, debonded, and then sintered. The optimum powder loading is 55 vol%. The ideal conditions of catalytic debinding were attained by placing the specimens in the catalytic debinding system at 120 °C temperature. Samples with minimal deformation and low impurity content were obtained when thermal debinding was carried out at a modest heating rate of 1.0 K/min and a holding time of 1.5 h. All the sintered samples have a similar microstructure, that is, lamellar α + β structure. The sample exhibits a strength of 739 MPa and an elongation of 6.1 % at the optimum sintering conditions (sintering at 1250 °C for 2 h). The samples prepared by MIM have excellent wear resistance. This process provided a straightforward and cost-effective means of producing complex-shaped titanium components from HDH Ti powder.

A comparison of fabrication routes and property evaluation methods for bio‐particulate filled glass‐epoxy composites

AbstractThis research work aims to investigate the effect of fabrication techniques on the physico‐mechanical properties of pistachio shell (PS) filled glass‐epoxy composites and to compare the experimental findings with numerical simulation results using finite element analysis (FEM). These hybrid composites are fabricated by vacuum‐assisted resin transfer molding (VARTM) and hand layup (HL) techniques with fixed glass fiber fraction (20 wt. %) but different PS powder loadings of 0–30 wt. %. The composites are then characterized for physical, compositional, micro‐structural and mechanical properties. The micro‐structural analysis of the filler and composites is performed using electron microscopy and stereo‐microscopy. To identify the phases present in both the raw filler and the composite, an x‐ray diffraction test is performed. The presence of functional groups is identified with the help of Fourier transform infrared spectroscopy (FTIR). It is observed that there is a reasonable improvement in the mechanical properties of the composites with increase in PS powder content, irrespective of the fabrication process used. The density and void fraction are also greatly affected by the amount of filler particles present in the composites and also on the composite fabrication technique. The FEM analysis is also carried out using ANSYS 22.0 workbench to determine the characteristic properties numerically. The comparison of experimental and numerical results yields that the properties obtained by using VARTM results are close to experimental ones with errors lying in the range of 1%–4%. These composites can possibly find potential applications in light duty structures and wear resistant applications.Highlights Development of hybrid composites using HL and VARTM techniques. Physical and mechanical properties alter with filler loading. Evaluation of mechanical properties using finite element analysis. Validating the model by comparing experimental and numerical results.

Binder System Composition on the Rheological and Magnetic Properties of Nd-Fe-B Feedstocks for Metal Injection Molding

The applications of Nd-Fe-B-based magnets are experiencing significant diversification to achieve efficiency and miniaturization in different technologies. Metal injection molding (MIM) provides new opportunities to manufacture Nd-Fe-B magnets with high geometrical complexity efficiently. In this study, the impacts of the binder system composition and powder loading on the rheological behavior, contamination, and magnetic properties of the Nd-Fe-B MIM parts were investigated. A high-pressure capillary rheometer was used to measure the apparent viscosity and pressure drops for feedstocks with different binder formulations and powder contents. Also, oxygen and carbon contamination, density, and magnetic properties were measured for different feedstock formulations and powder loadings. From the rheological, density, and magnetic properties points of view, the binder system consisting of 45 vol.% LLDPE as backbone was selected as the optimum formulation. The findings indicated that the sample with this binder system and 55 vol.% powder content had a high density (6.83 g/cm3), remanence (0.591 T), and coercivity (744.6 kA/m) compared to other binder compositions. By using 58 vol.% powder loading, the values of density (7.54 g/cm3), remanence (0.618 T), and carbon residue (982 ppm) improved, and a suitable rheological behavior was still observed. Thus, a suitable feedstock formulation was developed.

Ceramic fused filament fabrication (CF3) of alumina: Influence of powder particle morphology on processing and microstructure

This study investigates ceramic fused filament fabrication (CF3) 3D printing of alumina with an emphasis on the impact of particle morphology on feedstock preparation and printability. Spherical powder displayed superior flow with higher apparent density, tap density, and powder packing fraction compared to irregular powder. A 55 vol % powder loading was chosen to ensure good flowability during printing. Irregular powder-based feedstocks had 40X higher viscosity than spherical powder feedstocks at 400 s−1 shear rate, posing potential printing challenges. Slow printing speed maintained low feed-rates for consistent material flow. The debinding and sintering process produced macroscopically defect-free alumina components with relative densities above 89 % for both powder morphologies. The focus of the work is on comparing two different powder particle morphologies influencing feedstock behavior, printing fidelity, and sintered part properties.

A Taguchi-Simplex Algorithm for the Optimization of Tapped Density for Particulate Orange Peels

In the composite industry, green fillers transported between locations face undesirable impacts of road surface on powder loads but few methods accurately account for this challenge in tapped density measurements. The purpose of this paper is to introduce a methodology to help composite development engineers manage the transportation of orange particles in transit, on vehicles as they move from the particle production locations to the production process locations. In this paper, the Taguchi method-simplex algorithm (TM-SA) method is proposed for the tapped density optimization of orange peel particulates (OPPs). OPPs of 0.425 and 0.600mm for automobile applications are optimized using experimental data. Managing the transportation process of orange peel particulates and their outcomes needs managing substantial tapped density information. Taguchi method was integrated into the objective function of a simplex algorithm. The tapped density parameters were optimized at the lowest parametric values and the constraints were formulated. It was revealed that for the 0.425mm orange peel particulates, the optimal values and volumetric values were lower by 0.09% and lower by 4.06%, respectively. For the 0.600mm, the optimal values and volumetric values were higher by 0.005% and 6.91%, respectively, when the current method was compared with the literature values from the grey relational analysis. The results at optimality support the effectiveness of the method and were validated by the grey relational analysis results from the literature. The utility of our research is to help green filler powder manufacturers assure cost-effective decisions and logistics delivery optimization.

Optimisation of powder extrusion moulding process for thick ceramic electrodes of LiCoO2 for enhanced energy-density lithium-ion batteries

Lithium-ion batteries are widely used in portable electronic devices because of their high energy and power density. To enhance the energy density of these batteries, one strategy involves increasing the active material loading by increasing the thickness of the electrodes. In previous studies, we demonstrated that powder extrusion moulding (PEM) is a scalable and efficient method for producing additive-free LTO and LFP ceramic electrodes, which exhibit remarkable electrochemical performance with thicknesses up to 500 μm. This study focuses on the preparation and optimisation of the entire manufacturing process for thick ceramic electrodes of LiCoO2 (LCO) with a high mass loading of 180 mg cm−2 using the PEM process. Different powder loadings of mixtures of LCO and a thermoplastic multi-component binder were explored to obtain a formulation suitable for rheology. The optimal formulation comprises 60 vol% of powder. After binder removal via a combination of solvent and thermal treatment, followed by air sintering, parts with varying porosities were obtained. Striking a balance between porosity and thermal degradation is crucial for achieving optimal electrochemical behaviour. Electrochemical evaluations of the electrodes sintered at 900 °C and 1000 °C revealed areal capacity values as high as 17 mAh cm−2 at C/25 and 7 mAh cm−2 at C/6.25, respectively. These values far exceed the 1−2 mAh cm−2 obtained from commercial LCO electrodes. These results indicate a strategy for the production of electrodes to fabricate lithium-ion batteries with a low ratio of inactive materials and, therefore, with higher energy densities.

Vat photopolymerization based Photoinhibition aided Ceramic additive manufacturing (PinCAM)

Vat photopolymerization (VPP) in ceramic additive manufacturing (CAM) faces challenges due to high viscosity from ceramic powder loading, necessitating interruptive recoating steps. Ceramic particles also attenuate and divert irradiated light, causing reduced cure depth and over-curing, leading to slow print, weak interlay adhesion, and dimensional errors. This study introduces photo inhibition-aided CAM (PinCAM) using dual-wavelength digital light processing to mitigate these issues. PinCAM employs two optical masks for initiation and inhibition at different wavelengths. While previous research focused on polymers, this work evaluates inhibition's effects in suspension-based VPP-CAM. Modeling and experiments examine inhibition and curing characteristics, print speed, dimensional accuracy, surface roughness, and microstructure. Preliminary results suggest that photoinhibition has the potential to enhance geometrical and surface properties as well as particle distribution homogeneity of green ceramic components without significantly compromising print speed. Understanding inhibition's impact will aid further research in PinCAM optimization for rapid and precise ceramic manufacturing.

Impacts of Aramid Fiber (PPTA), Glass Wool (GW), Aluminum (Al), and Silicon Carbide (SiC) Particles on Mechanical Behavior of Epoxy Hybrid Composites and their Morphological Investigation

AbstractParticle‐reinforced polymer composites have figured prominently in technological appliances owing to their high mechanical modulus and strength. Due to the obvious demand for lighter but more resilient composites to substitute heavy metal parts, several investigations have been made into particle‐based composites. The current research investigates the impact of reinforcing aramid fiber (PPTA), glass wool (GW), aluminum (Al), and silicon carbide (SiC) powder into an epoxy matrix on aspects of mechanical and morphological characteristics. Hand lay‐up technology was performed to manufacture composites at five different degrees of reinforcement loading (5, 10, 20, 30, and 40 wt. %). SEM and optical microscopes were used for microstructural investigation in order to evaluate the cohesion and dispersion of the reinforcing particles across the matrix phase of the hybrid composites. The elongation at break, flexural strength, flexural modulus, and hardness of epoxy‐PPTA‐GW−Al‐SiC hybrid composites improved, whereas the tensile strength and impact strength decreased from 5 wt. % to 40 wt. % loading. Among fabricated hybrid composite compositions, the morphological and mechanical characteristics obtained at 40 wt. % PPTA, GW, Al, and SiC powder loading are the best among all others.

Emission Spectra of Uranium Particulates at High Temperature.

The emission spectrum of micron-scale uranium particulates at high temperatures in the ultraviolet, visible, and near-infrared spectral regions is investigated using a heterogeneous shock tube. Temperatures from 3000 to 9000 K are characterized in an inert argon environment and with incremental amounts of added oxygen. Atomic line spectra do not emerge above the continuum emission spectrum until between 4500 and 5000 K in pure argon, and 6100 and 6600 K in 1% oxygen. For 5% oxygen, however, the threshold for atomic emission drops below 3800 K. Uranium monoxide molecular emission in the strongest visible band at 595.4 nm is not observed at any condition. Uncertainties in particle temperature determination in high-temperature shock tube environments are discussed, and limitations to such measurements are presented, such as those from experimental factors such as the powder loading method and expected detection limits of uranium species in relevant conditions.

Enhancing lithium extraction from low grade salt lake brines using high powder loading aluminum-based adsorbent granules

Ensuring adsorbent granules with high homogeneity and powder loading are essential prerequisites for an efficient industrial adsorption. This study introduced novel aluminum-based lithium adsorbent granules to extract lithium from low grade salt lake brines, combining the antisolvent extrusion granulation strategy and high mixing power preparation. The comparative study revealed that these granules exhibited a vibration density of 850.00 g/L and a powder loading of 86 %, significantly higher than the conventional adsorbent granules. Besides, the superior hydrophilicity of these granules facilitated lithium adsorption kinetics, enabling them faster to reach equilibrium with the volumetric adsorption capacity of 4710.12 mg/L. Notably, during column experiments performed with Qarhan salt lake old brines, these granules demonstrated a remarkable adsorption performance with the volumetric adsorption capacity of 2791.00 mg/L after a 360 min feed period, underscoring their substantial promise in enhancing industrial lithium extraction efficiency.

Material extrusion additive manufacturing of WC-9Co cemented carbide

Additive manufacturing (AM) cemented carbide is primarily challenged by critical issues of difficult-to-eliminate pores, cracks, deleterious phases, and non-uniform microstructure, which result in poor mechanical properties. This study utilizes material extrusion (MEX) AM technology to prepare a WC-9Co cemented carbide. The results show that green body printing and solvent debinding process significantly affect its stacked voids, interlayer bonding defects, and debound cracks. These green body defects are eliminated through liquid phase flow and WC particles flow-rearrangement during sintering, resulting in Co-rich regions or Co pools, abnormal growth of WC grains, and residual pores. A green body free of visible defects is prepared using a feedstock with a powder loading of 54 vol%, a printing temperature of 150 ℃, a microfilament overlap ratio of 30 %, and a printing-layer thickness of 0.1 mm. Followed by a two-step solvent debinding and continuous thermal debinding-vacuum-pressure sintering, a nearly fully dense WC-9Co cemented carbide is fabricated, with a uniform microstructure of two phases and free of pores, cracks, and Co pools. Its Vickers hardness, transverse rupture strength, and fracture toughness reach 1525±3 HV30, 3492±45 MPa, and 20.4±0.5 MPa·m1/2, respectively, which are significantly better than those of similar reports and could be comparable to similar cemented carbides prepared by powder metallurgy. This study could provide a new technological path for developing high-performance cemented carbide complex-structured components.

Viscosity Analysis of Copper Aluminium Manganese (CuAlMn) Shape Memory Alloy Mixed with Polyethylene Glycol (Peg), Polymethyl Methacrylate Acrylic (Pmma) and Stearic Acid (Sa) Based Binder

Shape memory alloys (SMAs) are a class of smart materials that have the unusual feature of remembering the initial shape after plastic deformation. SMAs differ from traditional elastic/plastic materials in because of reversible hysteretic thermos mechanical behavior. Copper (Cu) based shape memory alloys are the most promising in terms of practical application due to their inexpensive cost and high recovery force. Powder injection molding (PIM) is well known for the creation of complex components (micro parts) and Copper Aluminium Manganese (CuAlMn) materials are studied through this process. The rheological behavior of the feedstock needs to be determined to avoid any nonhomogeneous mixture between powder and binder that may result in powder and binder separation during the injection molding process. This work focused on the rheological properties of CuAlMn with a binder system of polyethylene glycol (Peg), polymethyl methacrylate acrylic (Pmma) and stearic acid (Sa). The critical powder volume percentage of composite was at 85wt% Cu, 12wt% Al and 3wt% Mn was obtained. Based on such value, the powder loadings used in this work was 58wt% mixed with 73wt% Peg, 12wt% Pmma and 5wt% Sa. A capillary rheometer was employed for the rheological studies where the relationship between shear rate and viscosity was investigated. There were 3 variant temperatures (115℃, 125℃ and 135℃) and 4 loads (40N, 50N, 60N and 70N) applied for the rheology test. The obtained result shows that the overall shear rate and viscosity are within the PIM process recommended range and flow index is below 1. This shows pseudoplastic behavior of the feedstock.

Moldability and Solvent Debinding of Hydroxyapatite Micro-Part Processed through Micro-Powder Injection Molding

The development of the micro-powder injection molding (µPIM) process from the powder injection molding (PIM) process has been prompted by the demand of the worldwide market to produce micro-sized components. The need for µPIM-processed components is currently rising across a range of industries, including automotive, aerospace, food, biomedical, electronics, and telecommunications. In the current research work, homogeneous HA feedstock with a powder loading of 57 vol.% was prepared by mixing HA powder particles with palm stearin and low-density polyethylene (LDPE) binders at a mixing temperature of 150 °C for 6 h. Defect-free injection molded or green micro-sized components of HA were produced by employing injection pressure, injection time, mold temperature, and melt temperature of 12 bar, 5 s, 110 °C, and 180 °C, respectively. When mold temperatures less than 110 °C were used, short shot defects were frequently observed in green specimens. After solvent debinding at 60 °C for 50 min, 82.2% of the palm stearin was removed from the green part. No difference in dimension between the solvent debound part and the green part was noticed. An open-pore structure developed in the solvent debound HA microcomponent is helpful for eliminating the insoluble LDPE binder during the thermal debinding phase.

Strong and densified 3D metal-ceramic composite with strengthened layer structure by material extrusion additive manufacturing

Material extrusion (MEX) of high-filled polymers with metal or ceramic powders has showed great potential in fabricating 3D structure combined via the powder metallurgy route. However, defects between deposited layers adversely affect the final performance of 3D components. Here, we introduced a high-flow filling approach based on effective viscosity control and optimized printing strategies for preparing high-density NiFe2O4-based cermet. We investigated the influence of powder loading and filling paths on both green and sintered samples regarding density, microstructure and mechanical properties. Polyformaldehyde (POM)-based feedstocks were developed with powder loading of 62 vol% and 56 vol%. 3D cermet with high powder loading demonstrated good shape retention but contained periodic pores due to low-flow filling between adjacent filament. Cermets with high relative density were achieved using 56 vol% POM-based feedstock because of satisfactory fluidity and high-filling effect during deposition. Filling paths determined the distribution and size of the pores, with cermet based on the (45°, 135°) trace exhibiting the most uniform and dense structure. Cermets using 62 vol% feedstock showed significant differences in flexural strength depending on the filling path, much lower than those achieved with the high-flow filling approach. Finally, 3D NiFe2O4-based cermets utilizing 56 vol% feedstock demonstrated an optimal average flexural strength of 173.5 MPa, close to 178.4 MPa of conventional injection molded samples. Hence, high-qualified metal-ceramic composites can be fabricated using MEX via the high-flow filling approach, with potential applications in complex-shaped anode, cutting tools and wear-resistant parts.

The Effect of Eggshell Powder on the Properties of Purple Sweet Potato Starch/Eggshell Bioplastics

Petroleum-based plastics are derived from non-renewable sources and are supremely utilized in packaging industries due to their superior flexibility, mechanical and barrier properties. However, due to petroleum-based plastics do not degrading easily, researchers are turning into bioplastics. This study was conducted to examine the effect of eggshell powder (ESP) loadings on the physical and mechanical properties of purple sweet potato (PSP) starch bioplastics. PSP starch was extracted and mixed with glycerol as plasticizer and 0 – 40 % by weight of ESP to fabricate PSP/ ESP bioplastic using solution casting method. The incorporation of ESP in PSP starch matrix (in terms of functional groups and bonding existed) was analyzed by using Fourier Transform Infrared spectroscopy (FTIR-ATR). The physical property of PSP/ESP bioplastics is characterized through water absorption test. Whereas the mechanical properties (tensile strength, Young’s Modulus and elongation at break) of bioplastics was analyzed by tensile test. From FTIR analysis, it can be summarized that the PSP/ESP bioplastic was successfully synthesized. The tensile strength and modulus of this bioplastics increase from with the addition of ESP up to 20 wt.%. This is because further addition of ESP above 20 wt.% reduces tensile strength and modulus of elasticity of this bioplastic. In terms of elongation at break, a slight decrease in elongation at break as the ESP loadings increases. Similarly, the water absorption capacity of this bioplastic significantly decreases as the percentage of ESP increases. The incorporation of ESP into this bioplastic able to reduce rate of water absorption from 26.32 % to 12.5 % in 72 h. Therefore, these bioplastics exhibit good physical and mechanical properties that can be used as alternatives for synthetic plastic to cope with waste generation and disposal problems, especially in the food industry.

Plastic shaping of NiFe2O4‐based cermets using granular feedstock: microstructure and mechanical properties

AbstractCarbon‐free aluminum electrolysis is crucial for achieving the low‐carbon development and carbon neutrality in the future aluminum industry. NiFe2O4‐based cermet is the potential candidate of inert anode, benefiting from the satisfactory corrosion resistance and high‐temperature conductivity. Herein, complex‐shaped 25(Cu–20Ni)/(NiFe2O4–10NiO) cermets were fabricated via a plastic shaping method using the polyformaldehyde (POM)‐based granular feedstock. The feedstock showed uniform microstructure with evenly dispersed powders wrapped in polymers, which exhibited shear‐thinning behavior during molding. Roles of the feedstock with different powder loadings in the morphology and bending strength of the cermets were investigated. High‐precision gear parts exhibited no deformation, a high relative density over 98%. Investigation of different powder loadings revealed that parts prepared with a 56 vol% loading demonstrate the excellent performance, and possessed an impressive flexural strength of 178.4 MPa. This achievement provided a foundation for the future utilization of complex‐shaped inert anode material components in industrial applications.