3D Ceramic Structures Shrinkage Matching
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Solution Overview
Problem
Standard forming processes for ceramic articles face challenges in incorporating detailed 3D designs, being labor-intensive, time-consuming, and cost-inefficient, and struggle to maintain structural integrity and adhesion of 3D ceramic structures upon drying and firing.
Innovation Solution
A method of forming 3D ceramic structures by adding layers of ceramic mixture onto a ceramic substrate, where the drying shrinkage of the mixture is matched within ±5% of the substrate's shrinkage, ensuring stable structural integrity and adhesion, using techniques like 3D printing and controlled solvent and binder application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If standard forming processes (casting, extrusion, pressing) are used to create detailed 3D ceramic structures, then design detail is achieved, but the process becomes labor intensive, time consuming and cost inefficient
Solution Approach 1:
The invention changes the fundamental parameter of how ceramic structures are formed by transitioning from traditional form-based processes to digital modeling and additive manufacturing. Computer-aided design (CAD) models enable precise control of 3D geometry, while layer-by-layer deposition allows complex shapes to be built automatically, eliminating manual labor and significantly improving production efficiency while maintaining design detail
Solution Approach 2:
The invention replaces mechanical forming processes (casting molds, extrusion dies, pressing tools) with a digital-driven additive manufacturing system. The ceramic mixture is deposited layer-by-layer according to digital instructions, substituting complex mechanical forming systems with a more efficient digital control system that reduces labor intensity and production time
2Device complexity
If 3D structures are added onto ceramic substrates using conventional methods, then structural complexity is increased, but structural integrity and adhesion are compromised during drying and firing
Solution Approach 1:
The invention applies homogeneity by ensuring the ceramic mixture has matching shrinkage characteristics to the substrate. By formulating the mixture so its drying shrinkage is no more than 5% higher and no more than 5% lower than the substrate, the invention creates uniform dimensional behavior across the entire structure, preventing differential stress that would compromise adhesion and structural integrity during drying and firing
Solution Approach 2:
The invention employs beforehand cushioning by pre-matching the shrinkage properties of the ceramic mixture to the substrate before the drying and firing processes occur. This proactive approach anticipates and prevents potential adhesion failures by ensuring both materials undergo comparable dimensional changes, thereby cushioning against the development of detrimental stresses during subsequent processing
3Ease of operation
If ceramic mixture with high solvent content is used for 3D printing, then ease of deposition is improved, but drying shrinkage increases causing adhesion failure
Solution Approach 1:
The invention optimizes the solvent content parameter of the ceramic mixture to achieve a balanced state. By controlling the solvent concentration, the invention maintains sufficient fluidity for easy layer-by-layer deposition while limiting the amount of solvent that would evaporate during drying. This parameter optimization ensures the drying shrinkage remains within the critical ±5% range, preventing adhesion failure while preserving manufacturability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves desired structural integrity, adhesion, and flexibility in design, reducing production costs and time, while maintaining the integrity of the 3D ceramic structure during drying and firing.
Implementation Method 1
wherein the drying shrinkage of the ceramic mixture is no more than 5% higher and no more than 5% lower than the drying shrinkage of the ceramic substrate
Implementation Method 2
wherein the firing shrinkage of the ceramic mixture is no more than 1.5% higher and no more than 1.5% lower than the firing shrinkage of the ceramic substrate
Data Source
Figure 1
AI summary
The present invention relates to a method of forming a 3D ceramic structure by adding a 3D structure with one or more layer(s) of ceramic mixture onto a ceramic substrate. The present invention also relates to a 3D ceramic structure as well as to a green 3D ceramic structure.