Additive Manufacturing of Ceramic-based Materials: Process Development, Materials, Process Optimization and Applications: Session II: Extrusion-based AM and Stereolithography
Sponsored by: ACerS Engineering Ceramics Division, ACerS Basic Science Division, ACerS Manufacturing Division
Program Organizers: Xuan Song, University of Iowa; Lei Chen, University of Michigan-Dearborn; Xiangyang Dong, Arizona State University; Yiquan Wu, Alfred University; Paolo Colombo, University of Padova; Rajendra Bordia, Clemson University; Long-Qing Chen, The Pennsylvania State University
Monday 2:00 PM
October 18, 2021
Room: A112
Location: Greater Columbus Convention Center
Session Chair: Yiquan Wu, Alfred University; Xuan Song, University of Iowa
2:00 PM
Multifunctional Artificial Artery from Direct 3D Printing with Built-in Ferroelectricity and Tissue-Matching Modulus: Jun Li1; 1University of Wisconsin-Madison
In this work, electric field-assisted 3D printing technology was developed to fabricate in situ-poled ferroelectric artificial arteries that offered battery-free real-time blood pressure sensing and occlusion monitoring capability. The functional artery architecture was made by the development of a printable ferroelectric bio-composite that could be quickly polarized during printing and reshaped into devised objects. Synergistic effect from the ferroelectric potassium sodium niobate (KNN) particles and the ferroelectric polyvinylidene fluoride (PVDF) polymer matrix yielded a superb piezoelectric performance (d33 > 12 pC N-1, confirmed by piezometer) on a par with that of commercial ferroelectric polymers. The sinusoidal architecture brought the mechanical modulus down to the same level of human blood vessels. The 3D-printed artificial artery provided an excellent sensitivity to pressure change (0.306 mV/mmHg, R2> 0.99) within the range of human blood pressure. The ability to detect subtle vessel motion change enabled early detection of thrombosis, allowing for preventing grafts failure.
2:20 PM
Direct-write 3D Printing of Electrodes for High Power Density Batteries: Amjad Almansour1; Mrityunjay Singh2; Michael Halbig1; Daniel Gorican3; 1NASA Glenn Research Center; 2Ohio Aerospace Institute at NASA Glenn Research Center; 3HX5, LLC at NASA Glenn Research Center
The development of batteries with high specific power and energy densities will enable more efficient implementation of all-electric aircraft and urban air mobility (UAM) technologies. Additive manufacturing technologies can be leveraged to produce engineered 3-dimensional cell structures with increased electrolyte/electrode interfacial area and high density, yielding increased power and energy densities. Direct-write additive manufacturing (DWAM) technology allows for the deposition of highly solid-loaded inks with excellent dimensional accuracy. Ink rheology was adjusted to optimize material characteristics of the final electrodes, including the addition of carbon nanoparticles to increase the final electrode conductivity. Engineered LiFePO4 (LFP) cell structures were manufactured, sintered, and characterized by leveraging the submicron accuracy of direct write printing. The scanning electron microscopy of sintered electrodes show dispersion of conductive carbon nanopowders throughout the microstructure. Theoretical estimation of surface area of engineered microstructures in this study show the potential of doubling the final power density using this design.
2:40 PM Invited
The Influence of Processing on the Mechanical Properties of Additively Manufactured Ceramic Matrix Composites: Mark O'Masta1; Ekaterina Stonkevitch1; Kaleigh Porter1; Phuong Bui1; Natalie Larson2; Zak Eckel1; Tobias Schaedler1; 1HRL Laboratories LLC; 2Harvard University
Additive manufacturing (AM) of ceramic matrix composites (CMCs), comprising a polymer-derived Si(O)C ceramic matrix, allows for free-from part fabrication with tailorable thermal and mechanical properties. Realizing these potential gains requires controlling multiple phase changes, as the silicon-based, pre-ceramic resin (PCR) is printed on light-based printers and converted into a CMC after a pyrolysis heat treatment, as well as understanding the interaction with the embedded reinforcement. Here, we pair numerical analysis with experimental studies, including in-situ X-ray computed tomography (XCT) of the pyrolysis event, to unveil the necessary conditions for converting the polymer to ceramic without the formation of deleterious cracks and voids. We test the influence of processing conditions on mechanical properties using printed ceramics reinforced with particles and whiskers. Unresolved questions and opportunities in CMC processing will be highlighted.
3:10 PM
Additive Manufacturing of Yttrium-stabilized Zirconia Architectures with Stretch-dominated Mechanical Properties: Hunter Rauch1; Kendall Knight1; Huachen Cui2; Jake Yoder1; Xiaoyu Zheng2; Hang Yu1; 1Virginia Polytechnic Institute and State University; 2University of California, Los Angeles
Cellular ceramic structures can sustain high loads before fracturing and dissipate substantial energy during post-fracture densification. Ceramic 3D printing via stereolithography can create arbitrary geometries at fine resolution, including cellular structures, but there are significant challenges associated with designing the ceramic resin. Zirconia has been successfully 3D printed, but there is a dearth of results supporting 3D printed cellular zirconia architectures in load bearing applications. Here, we design a zirconia resin for stereolithography to minimize viscosity and maximize green density, based on which hexagonal-cell honeycombs are printed. After sintering, we test the mechanical properties by out-of-plane ‘sandwich panel’ compression and find that the performance and failure behavior are limited by the geometry rather than any manufacturing defects, which would include interlaminar defects or porosity. This observation highlights the promise of the presented manufacturing routes for architectured zirconia, while also stressing the needs for rational architecture design of cellular ceramics.
3:30 PM Break
3:50 PM
Characterization of Anisotropic Structure of Additive Manufactured Ceramics: Rosario Gerhardt1; Yifan Jin1; Zev Greenberg1; Shawn Allan2; 1Georgia Institute of Technology; 2Lithoz America, LLC
Lithography-based ceramic manufacturing (LCM) was used to make 3YSZ and alumina parts in a Lithoz CeraFab 3D printer. In LCM, ceramic powders are suspended in a photocurable resin system, which is structured into a green part through repeated exposure to light which cures the resin. After the green part is produced, it is post processed to remove the resin binder and sinter the ceramics. Half of the samples were sintered to achieve a typical maximum density, and half were sintered at a lower temperature to leave approximately 20% porosity in the samples. AC electrical based methods (dielectric properties and impedance spectroscopy) were used to determine the structure-property-processing relationships aided by microscopy and CT scanning methods. It was found that the incompletely sintered specimens showed a much bigger dependence on humidity than those that were sintered to full density. The z-direction samples showed more insulating behavior than those in the xy-plane.
4:10 PM Invited
3D Printing of Nd:YAG Laser Ceramics through Lithography-based Light Projection: Guangran Zhang1; Yiquan Wu1; 1Alfred University
Y3Al5O12 (YAG) has the major applications including laser gain media, LED and displays, scintillators, etc. For developing a complex geometry of transparent ceramics, it would be very challenging for conventional shaping methods to form required structures by powder pressing or slurry mold casting. In this presentation we report a digital light projection (DLP) printing method to fabricate three-dimensional (3D) transparent Nd:YAG ceramics. Commercial Lithoz CeraFab 8500 3D ceramic printer was used to process ceramics green body with resolution up to tens of micrometers. Followed by thermal treatment, 3D printed ceramic green body could be sintered to transparent ceramics without any crack or bubbling issues. Fabricated Nd: YAG laser ceramics exhibited a relative density of 99.9 % and achieved an in-line transmittance of 80 % in the visible wavelength. This work demonstrates general feasibility and potential commercialization of lithography-based DLP for printing laser-grade transparent ceramics with customized 3D structures.
4:40 PM
Enhanced Piezocomposite Transducers with 3D Printed Piezoelectric PZT: Shawn Allan1; Nicholas Voellm1; Justin Tufariello2; Barry Robinson3; Alex Angilella2; Leslie Riesenhuber2; Brian Pazol3; 1Lithoz America LLC; 2The MITRE Corporation; 3MSI Transducers Corp.
Ceramic Additive Manufacturing (AM) enables fabrication of piezocomposite transducers with novel geometries that can achieve new levels of performance for underwater acoustics, including increased transducer sensitivity and improved directionality. These favorable characteristics promise enhanced sensing performance on compact and autonomous watercraft where efficiency is critical and spatial aperture may be limited. The project team collaborated to create innovative structures in PZT-5H using lithography-based ceramic manufacturing (LCM) from Lithoz. MSI created printable ceramic powders for slurry creation and refined post-processing procedures for repeatable sintered material properties (density, dielectric constant, and piezoelectric coefficient) equivalent to conventionally produced bulk ceramic. Piezocomposite transducers produced with printed PZT were compared against conventionally manufactured replica transducers with excellent performance matching. MITRE utilized coupled-acoustic finite element analysis (FEA) to design and evaluate distributed composite apertures and auxetic structures with improved performance, which are only feasible to manufacture with AM.
5:00 PM
Stereolithography Printing of Technical Ceramics and Its Applications: Kenna Ritter1; Peter Durcan1; 13DCERAM SINTO INC
For over 10 years 3DCERAM has been a pioneer in the realm of ceramic additive manufacturing. 3DCERAM offers turn-key ceramic printer lines, dedicated materials (3DMix), and printer services.Additive manufacturing of technical ceramics expands the capabilities of what can be manufactured. As with other additive manufacturing techniques, printing parts with certain complex geometries is now possible and with the added benefit of no tooling costs. There are a wide variety of possible applications for such technology such as biomedical, aerospace, electronics, foundry cores, and many others. In the foundry industry there is a lot of interest in manufacturing increasingly complex ceramic cores to meet the demands of evolving turbine blade designs. Ceramic additive manufacturing finds a niche application for aerospace manufacturing in making optical mirror components. In the biomedical field, 3DCERAM has developed materials such as HAP, TCP, etc. for a wide range of biomedical implant applications.