Binderless Ceramic Additive Manufacturing via Hydrothermal Jet Fusion
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Solution Overview
Problem
Ceramic structures produced by additive manufacturing (AM) processes typically have low density due to the use of organic binders, which are difficult to remove and result in porous products.
Innovation Solution
An additive manufacturing method involving the deposition of ceramic layers, contact with a saturant, heating to 50° C. to 300° C., and applying pressure up to 800 MPa to partially dissolve and fuse the ceramic particles, achieving densities ranging from 65% to 100% of fully densified products without the need for organic binders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If organic binders are used in ceramic additive manufacturing to form green bodies, then the structural integrity during manufacturing is improved, but the final product density deteriorates due to porosity and difficulty in binder removal
Solution Approach 1:
The invention removes organic binders entirely from the ceramic additive manufacturing process. Instead of using binders to form green bodies, the process uses binderless ceramic powder formulations with optimized particle size distributions and shapes that provide inherent green strength, eliminating the source of porosity and density issues
Solution Approach 2:
The invention changes the physical and chemical parameters of the ceramic powder system by using specific particle size distributions, surface treatments, and powder compaction parameters to achieve sufficient green strength without organic binders, thereby enabling high-density final products
2Ease of manufacture
If organic binders are used in ceramic additive manufacturing, then the ease of manufacture is improved, but the manufacturing complexity increases due to post-processing requirements for binder removal and densification
Solution Approach 1:
The invention extracts and eliminates the binder removal and densification post-processing steps by using binderless ceramic powders that achieve high density directly through controlled atmospheric sintering, simplifying the overall manufacturing process
Solution Approach 2:
The invention performs preliminary optimization of powder characteristics and compaction parameters during the manufacturing stage itself, so that the green body has sufficient strength and density without requiring subsequent binder removal or extensive densification processing
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 produces ceramic products with higher density and strength, eliminating the need for post-processing densification and binder removal, resulting in products with reduced porosity and improved mechanical properties.
Implementation Method 1
at least partially dissolving a portion of an external surface of a ceramic particle of the first layer of the first ceramic material, the second layer of the second ceramic material, or both
Implementation Method 2
heating the first layer of the first ceramic material, the second layer of the second ceramic material, or both to a temperature in a range of from about 50° C. to about 300° C.
Implementation Method 3
applying pressure to the first layer of the first ceramic material, the second layer of the second ceramic material, or both. The pressure can be in a range of from about 0 Pa to about 800 MPa
Implementation Method 4
fusing a portion of the dissolved portion of the external surface of the ceramic particle to form a product having a density in a range of from about 65% to about 100% relative to a corresponding fully densified product
Data Source
AI summary
Various embodiments of the present disclosure provide an additive manufacturing method. The method includes forming a first layer of a first ceramic material and forming a second layer of a second ceramic material. The method further includes contacting the first layer of the first ceramic material, the second layer of the second ceramic material, or both with a saturant. The method further includes heating the first layer of the first ceramic material, the second layer of the second ceramic material, or both to a temperature in a range of from about 50° C. to about 300° C. The method further includes applying pressure to the first layer of the first ceramic material, the second layer of the second ceramic material, or both. The pressure can be in a range of from about 10 kPa to about 800 MPa. The method further includes at least partially dissolving a portion of an external surface of a ceramic particle of the first layer of the first ceramic material, the second layer of the second ceramic material, or both. The method further includes fusing a portion of the dissolved portion of the external surface of the ceramic particle to from a product having a density in a range of from about 65% to about 100% relative to a corresponding fully densified product and optionally containing no organic binder.