Ceramic 3D Printing Shrinkage Reduction via Aqueous Binder
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Solution Overview
Problem
Ceramic products face significant shrinkage issues during processing, which can lead to dimensional inaccuracies and porosity, making it challenging to achieve precise and durable ceramic objects using modern technologies.
Innovation Solution
A method utilizing a powder-based 3DP system with a ceramic binder composed of water and polyvinyl alcohol, excluding solid organic binders, to reduce shrinkage and enhance the density of ceramic objects, allowing for the production of ceramic precursor articles with specific compositions and layer compression to maintain shape integrity during firing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If organic binders such as cellulose are used in the ceramic powder, then the ceramic object can be formed and bound during processing, but the object experiences greater reduction (shrinkage) and develops porosity during firing
Solution Approach 1:
The patent removes organic binders (such as cellulose) from the ceramic powder composition entirely. By extracting the harmful organic component, the invention eliminates the source of excessive shrinkage and porosity while maintaining binding strength through alternative means (aqueous binder system with controlled drying and firing processes).
Solution Approach 2:
The invention changes the binder system from organic-based to aqueous-based, and modifies the drying and firing parameters to accommodate this change. The aqueous binder allows for controlled evaporation and firing that prevents excessive shrinkage while maintaining adequate green strength throughout processing.
2Ease of manufacture
If traditional ceramic processing methods are used, then ceramic objects can be produced, but shrinkage as high as 20 percent occurs during drying, firing or hot pressing
Solution Approach 1:
The patent modifies processing parameters including using an aqueous binder system, controlling drying rates, and optimizing firing schedules to reduce shrinkage from 20% to less than 15%. These parameter changes maintain ease of manufacture while significantly improving dimensional control.
Solution Approach 2:
The invention uses a composite powder formulation combining ceramic particles with an aqueous binder system rather than organic binders. This composite approach enables traditional processing methods to be used while achieving reduced shrinkage and improved dimensional accuracy.
3Stability of the object's composition
If organic binding material is added to clay recipes, then the ceramic object can be formed and maintained during processing, but the object develops porosity and suffers deformations when exposed to high heat
Solution Approach 1:
The patent extracts removes organic binding material from the clay recipe entirely, replacing it with an aqueous binder system. This extraction eliminates the harmful effect of organic combustion during firing that causes porosity and deformation, while the aqueous system provides adequate structural integrity through controlled drying and firing.
Solution Approach 2:
The invention converts the potential harm of binder removal into a benefit by using an aqueous binder that evaporates cleanly without leaving porosity. The controlled drying process actually benefits the final product by creating a more uniform structure with reduced porosity compared to organic binder systems.
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
The method achieves a shrinkage reduction of less than 15% and produces ceramic articles with improved density and strength, comparable to traditional ceramics, enabling precise and durable ceramic pieces with reduced porosity.
Implementation Method 1
employs ink-jet technology to apply a specific ceramic binder to thin layers of ceramic precursor powder
Implementation Method 2
The compression mechanism is lowered onto the deposited layers and compresses the deposited layers to a reduced thickness
Implementation Method 3
subjecting the ceramic precursor article to heat for sufficient time to form a ceramic article
Data Source
AI summary
The present invention includes a method of preparing a ceramic precursor article, the ceramic precursor made thereby, a method of making a ceramic article and an article made by that method. It also includes a method of replicating a ceramic shape.