3D Printed Ceramic Objects with Carbon Reinforcement
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Solution Overview
Problem
Conventional 3D printed ceramic structures require high firing temperatures, leading to shrinkage, asymmetric deformations, and cracking, resulting in poor net shape fidelity and increased manufacturing costs.
Innovation Solution
A method involving carbonization of 3D printed ceramic structures by adding a carbon precursor to the ceramic printing medium, allowing for pyrolysis at lower temperatures, which introduces a network of carbon bonds, reducing shrinkage and improving structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If high firing temperatures are used to sinter the 3D printed ceramic structure, then the ceramic object achieves sufficient strength and structural integrity, but the structure undergoes shrinkage and asymmetric deformations resulting in poor net shape fidelity
Solution Approach 1:
The patent applies preliminary action by embedding carbon precursor material into the ceramic printing medium before the 3D printing process. This precursor material is then carbonized during firing to form a carbon-reinforced ceramic composite structure. The carbon network formed in advance during the printing and initial firing stages provides structural support that prevents shrinkage and deformation at high temperatures, thereby maintaining net shape fidelity while achieving the required strength.
2Strength
If high firing temperatures are used to form the ceramic object, then the ceramic structure achieves sufficient strength, but the manufacturing costs increase due to high grade equipment and energy consumption
Solution Approach 1:
The patent employs composite materials by creating a carbon-reinforced ceramic composite through the carbonization of embedded carbon precursor material. This composite structure achieves the required structural integrity at lower firing temperatures compared to conventional pure ceramic sintering. The carbon network acts as a reinforcement phase that strengthens the ceramic matrix, allowing the use of lower temperature kilns and reducing energy consumption while maintaining the necessary strength for applications such as foundry filters.
3Strength
If high firing temperatures are used to sinter the ceramic structure, then the ceramic object achieves sufficient strength, but the production time increases due to heating and cooling time requirements
Solution Approach 1:
The carbon-reinforced ceramic composite enables reduced firing temperatures, which directly decreases both the heating time to reach sintering temperature and the overall cycle time. The carbon network provides structural support that allows for faster heating rates and lower peak temperatures, thereby reducing the time required for the firing process while still achieving the necessary structural integrity for the ceramic object.
4Strength
If high firing temperatures are used to form the ceramic object, then the ceramic structure achieves sufficient strength, but the structure may undergo asymmetric deformations or even crack
Solution Approach 1:
The carbon precursor material is embedded into the ceramic printing medium before printing, creating a distributed carbon reinforcement network throughout the green body. During the firing process, this carbon is converted to a stable carbonized structure that reinforces the ceramic matrix. This preliminary incorporation of carbon reinforcement prevents asymmetric deformations and cracking that would otherwise occur during high-temperature sintering, thereby improving structural stability and reliability of the final ceramic object.
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 approach reduces the need for high firing temperatures, minimizing shrinkage and deformation, while enhancing the structural strength and fidelity of the resultant ceramic objects, thus lowering manufacturing costs and time.
Implementation Method 1
carbonizing and pyrolyzing the 3D printed ceramic porous structure so as to introduce and form a network of carbon bonds to the 3D printed ceramic porous structure
Data Source
AI summary
Certain examples relate to a method for manufacturing a ceramic object derived from a 3D printed ceramic structure. The method includes carbonizing the 3D printed ceramic structure. Such carbonizing of the 3D printed ceramic structure may include introducing a network of carbon bonding into the 3D printed ceramic structure via: impregnating and/or coating the 3D printed ceramic structure with a carbon precursor, or printing the 3D printed ceramic structure using a ceramic printing medium including a carbon precursor. The resultant 3D printed ceramic structure which includes a carbon precursor is pyrolyzed so as to form a network of carbon bonding within/surrounding the 3D printed ceramic structure.