Optimized Zirconia 3D Printing Using Digital Light Processing with Continuous Film Supply and Recyclable Slurry System

Stereolithography (SL) can fabricate complex ceramic parts layer by layer using computer-aided design (CAD) models. The traditional SL system utilizes a vat filled with ceramic slurry with a high solid content, which for ceramics contributes to several limitations and operational difficulties, and f...

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Bibliographic Details
Published in:Materials 2021-06, Vol.14 (13), p.3446
Main Authors: Sarwar, Waqas Ahmed, Kang, Jin-Ho, Yoon, Hyung-In
Format: Article
Language:English
Subjects:
3-D printers
Additive manufacturing
CAD
Ceramics
Computer aided design
Continuous casting
Density
Lithography
Microhardness
Optimization
Performance evaluation
Polymerization
Recycling
Sintering
Slurries
Tape casting
Three dimensional printing
Viscosity
Zirconium dioxide
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Summary:Stereolithography (SL) can fabricate complex ceramic parts layer by layer using computer-aided design (CAD) models. The traditional SL system utilizes a vat filled with ceramic slurry with a high solid content, which for ceramics contributes to several limitations and operational difficulties, and further renders it nonrecyclable mainly due to the presence of printed residue and its high viscosity. In this study, we utilized a continuous film supply (CFS) system integrated with a tape-casting type digital light processing (DLP) printer to fabricate zirconia prototypes with a solid content of 45 volume percent (vol.%). Various printing and postprocessing parameters were studied for optimization, to achieve a relative density of 99.02% ± 0.08% with a microhardness of 12.59 ± 0.47 GPa. Slurry reusability was also demonstrated by printing with recycled slurry to produce consistent relative density values in the range of 98.86% ± 0.02% to 98.94% ± 0.03%. This method provides new opportunities for material recycling and the fabrication of dense complex ceramic products, reducing the consumption of the material.
ISSN:1996-1944
1996-1944
DOI:10.3390/ma14133446