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Additive manufacturing process for producing ceramic articles using a sol containing nano-sized particles
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A technology for ceramic products and additive manufacturing, applied in additive processing, manufacturing tools, additive manufacturing, etc., can solve problems such as limiting mechanical properties, optical properties, final material properties, not suitable for high-precision ceramic products, limiting theoretical density percentage, etc.
Active Publication Date: 2018-01-26
3M INNOVATIVE PROPERTIES CO
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Problems solved by technology
Not only are the slurry properties generally unsuitable for making high-precision ceramics, but the larger particle size limits the percentage of theoretical density that can be achieved even when densely packed, thus limiting the final material including mechanical as well as optical properties characteristic
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[0112] According to another embodiment, the method comprises the steps of:
[0113] (a) providing a printing sol comprising nanoparticles, a solvent, a radiation curable monomer, a photoinitiator, optionally an organic dye, and optionally an inhibitor as described herein,
[0114] (b) processing the printing sol as a construction material in an additive manufacturing method to obtain a three-dimensional article in a gel state, the three-dimensional article having a volume A,
[0115] (c) Additive fabrication of the desired geometry by photocuring,
[0116] (d) optionally cleaning the surface of the three-dimensional article in the gel state, in particular for the purpose of removing unreacted sol residues,
[0117] (e) optionally post-curing (for example, by heating or photocuring) the three-dimensional article in the gel state to a temperature in the range of 35°C to 80°C, or by additional photocuring, in particular for increasing the gel state. The purpose of the stability...
Embodiment approach OD1
[0549] A method for making a ceramic product, the method comprising the steps of:
[0550] Provide a printing sol comprising nanoscale zirconia particles, a radiation curable component and a photoinitiatorsystem;
[0551] Processing of the printing sol as construction material in an additive manufacturing method to obtain a three-dimensional article in a gel state, the three-dimensional article having a volume A;
[0552] Application of a supercritical drying step to the three-dimensional article in the gel state;
[0553] • Applying a heat treatment step to obtain a sintered three-dimensional ceramic article having a volume F.
Embodiment approach OD2
[0555] According to the method of the preceding embodiments, the volume A of the three-dimensional article in the gel state exceeds 200% of the volume F of the ceramic article in its sintered state.
[0556] The printing sols described in embodiments OD1 to OD8 can be made and processed in the same manner as the other printing sols described herein.
[0557] The invention also relates to a method of making a three-dimensional article comprising the step of processing a printing sol as described herein by using or applying an additive manufacturing technique as described herein.
[0558] The present invention also relates to a zirconia gel body obtainable or obtained according to the method described herein, preferably a zirconia airgel body or a zirconia xerogel body.
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Abstract
The present invention relates to a process for producing a ceramic article, the process comprising the steps of providing a printing sol, the printing sol comprising solvent, nano-sized particles, radiation curable monomer(s) and photoinitiator, the printing sol having a viscosity of less than 500 mPa*s at 23 DEG C, processing the printing sol as construction material in an additive manufacturingprocess to obtain a 3-dim article being in a gel state, the 3-dim article having a Volume A, transferring the 3-dim article being in a gel state to a 3-dim article being in an aerogel state, heat treating the 3-dim article to obtain a sintered 3-dim ceramic article, the ceramic article having a Volume F, Volume A of the 3-dim article in a gel state being more than 500% of Volume F of the ceramic article in its sintered state. The invention also relates to a ceramic article obtainable according to such a process. The ceramic article can have the shape of a dental or orthodontic article.
Description
technical field [0001] The present invention relates to an additive manufacturing method for making ceramic articles using a sol containing nanoscale particles as a construction material. The invention also relates to ceramic articles obtainable by such methods. The invention is particularly suitable for use in the field of dentistry and orthodontics in the manufacture of dental restorations and orthodontic brackets. Background technique [0002] In conventional ceramic processing such as slip casting, the ceramic slurry must generally have as high a particle loading as possible in order to obtain an intermediate body with a high green density. High green density is desired and required for making densely sintered ceramics. [0003] In powder-based additive manufacturing techniques, the low packing density of the powderbed leads to highly porous 3D objects, which usually cannot achieve high-density ceramics without applying large pressures during heat treatment, thus enab...
Claims
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