Ceramic 3D Printing Adhesive-Cement Binding System
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Solution Overview
Problem
Current three-dimensional printing technologies face challenges with ceramic materials, particularly in terms of reliability and recyclability, as well as limitations in temperature range and waste generation, due to instability of ceramic slurries and the use of non-recyclable materials like furan resin.
Innovation Solution
A general-purpose adhesive-cement binding system is developed using a powdered material with a nonreactive ceramic filler, a two-component cement, and a nonaqueous jetting fluid, which forms a solid 'green' article that retains shape during handling and can be heat-treated, with most of the binding material burning off during firing, leaving a ceramic component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ceramic slurry is used with continuous-jet inkjet printhead, then ceramic components can be produced, but reliability deteriorates due to slurry instability and wear on jetting apparatus
Solution Approach 1:
The invention extracts the problematic liquid binder from the ceramic material system and replaces it with a dry powder binder (plaster). This eliminates slurry instability and wear on jetting apparatus while maintaining the ability to form ceramic components through selective binding of ceramic particles.
Solution Approach 2:
The invention changes the physical state of the binder from liquid (slurry) to solid (dry powder), and changes the jetting fluid from organic-based to water-based. This parameter change improves reliability by eliminating slurry instability and apparatus wear, while the water-based fluid provides better control and reduced toxicity.
2Manufacturing precision
If gypsum plaster is used as active filler, then high accuracy is maintained, but temperature range is limited to about 1000 °C
Solution Approach 1:
The invention uses composite materials consisting of plaster binder combined with ceramic particles (such as alumina, silica, or zirconia) that have high melting points. This composite structure allows the component to withstand temperatures above 1000 °C while maintaining the dimensional accuracy provided by the plaster binder during the printing process.
3Temperature
If furan resin and methanesulfonic acid are used for high-temperature metal castings, then temperature range is extended, but recyclability is lost and toxic waste is generated
Solution Approach 1:
The invention converts the traditionally harmful organic resin binder system into a beneficial water-based system where the binder is composed of water-soluble materials. This allows the binding agents to be easily removed by washing with water, eliminating toxic waste while extending temperature capability through the use of high-melting-point ceramic particles in the composite structure.
4Reliability
If Portland cement with foundry sand is used, then recyclability and high-temperature capability are achieved, but versatility for general-purpose ceramics is reduced
Solution Approach 1:
The invention creates a universal system where water-soluble plaster binders can be combined with various types of ceramic particles (alumina, silica, zirconia, etc.) to produce different ceramic components for multiple applications. This multi-functional approach maintains recyclability through water washing while enabling versatility across different ceramic material systems and applications.
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 solution provides a reliable and recyclable method for producing ceramic components with high accuracy and stability up to 1450 °C, while minimizing waste and environmental impact, and allows for the use of a wide range of ceramic fillers, enhancing the versatility of 3D printing for ceramic applications.
Implementation Method 1
The jetting fluid is substantially nonaqueous (i.e., less that 50 wt% water), and the powder is a powdered soluble adhesive including a two-component (acid-base) cement
Implementation Method 2
a two-component (acid-base) cement
Implementation Method 3
Most of the binding material burns off during firing, leaving an article that is substantially comprised of the ceramic filler of choice
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
A powder for three-dimensional printing including a mixture of soluble adhesive; cement filler including magnesium oxide, and acid additive; and nonreactive ceramic filler. A kit includes a substantially nonaqueous liquid jetting fluid, and a solid powder mixture including soluble adhesive, magnesium oxide, an acid additive, and a nonreactive ceramic filler. A nonaqueous liquid jetting fluid includes up to 50 wt% cosolvents, and an acidic additive. A method for forming a three dimensional article includes providing a layer of a powder mixture including a soluble adhesive, magnesium oxide, an acid additive, and a nonreactive ceramic filler; and applying a substantially nonaqueous liquid jetting fluid including less than 50% water by weight to the powder mixture layer. A solid article formed by three-dimensional printing includes a solidified combination of a powder mixture including soluble adhesive, magnesium oxide, acid additive, and nonreactive ceramic filler; and a substantially nonaqueous liquid jetting fluid.