Water-Based Ceramic 3D Laminate Material and Method
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Solution Overview
Problem
Conventional 3D printing technologies using oil-based slurries face issues with high viscosity, poor fluidity, bubble formation, and the need for toxic solvents, leading to complex processes, health risks, and environmental hazards, as well as the requirement for additional support members and complicated cleaning procedures.
Innovation Solution
A water-based ceramic three-dimensional laminate material and method that replaces support members with a sacrificial layer, utilizing a slurry composed of material powder, photo-curable resin, and additives, which can be cured with visible or ultraviolet light, allowing for efficient formation and recycling of ceramic objects without toxic solvents and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If oil-based slurry is used in conventional 3D printing, then the slurry can be cured to form ceramic objects, but the high viscosity results in poor fluidity, difficulty in dispersion, and bubble formation
Solution Approach 1:
The patent changes the chemical composition parameters of the slurry by replacing oil-based binders with water-based photo-curable resins. This fundamental parameter change transforms the slurry from high viscosity and poor fluidity to low viscosity and excellent fluidity, while maintaining the ability to be cured and form ceramic objects. The water-based formulation with photo-curable resin enables both easy processing and reliable curing.
Solution Approach 2:
The patent uses a composite material system consisting of ceramic powder suspended in a water-based photo-curable resin matrix. This composite formulation combines the benefits of water-based fluids (low viscosity, good fluidity) with the curing capabilities of photo-curable resins, resolving the contradiction between ease of manufacture and reliability.
2Ease of manufacture
If oil-based slurry is diluted with highly volatile solvents to reduce viscosity, then the fluidity improves, but toxic substances are released and air quality deteriorates
Solution Approach 1:
The patent changes the solvent base from organic volatile solvents to water as the primary solvent. This parameter change eliminates the need for highly volatile toxic solvents while achieving the desired viscosity reduction through water-based formulation combined with photo-curable resin chemistry. The result is improved fluidity without harmful emissions.
Solution Approach 2:
The patent converts the typically harmful role of solvents into a beneficial one by using water as a non-toxic solvent that provides both viscosity reduction and environmental safety. The photo-curable resin system allows the water-based slurry to maintain stability and then cure properly, turning what would normally be a problematic water-based formulation into an advantageous eco-friendly solution.
3Reliability
If support members are used to support the slurry body during curing, then the body stability improves, but the process complexity and cost increase
Solution Approach 1:
The patent implements a self-service mechanism where the uncured photo-curable resin slurry itself provides support to subsequent layers during the curing process. The uncured material acts as a natural support medium, eliminating the need for separate support members. This self-supporting capability simplifies the device and reduces process complexity while maintaining body stability.
Solution Approach 2:
The uncured photo-curable resin serves as an intermediary substance that provides mechanical support between the curing layer and the build platform or surrounding structure. This intermediary uncured material fulfills the support function that would otherwise require additional support members, reducing device complexity.
4Reliability
If conventional slurry is used, then ceramic objects can be formed, but the cleaning process is complicated and time-consuming
Solution Approach 1:
The patent changes the chemical composition to water-based photo-curable resin, which fundamentally alters the cleaning requirements. Instead of requiring prolonged soaking in organic solvents, the water-based formulation can be easily cleaned with water or mild solvents, dramatically reducing cleaning time and simplifying the process while maintaining object formation capability.
5Reliability
If conventional oil-based slurry is used, then ceramic objects can be manufactured, but uncured slurry cannot be recycled and must be disposed of
Solution Approach 1:
The patent implements a recovery system where uncured photo-curable resin slurry can be collected, filtered to remove ceramic powder, and reused in subsequent printing operations. This recovering mechanism eliminates waste of the expensive photo-curable resin material while maintaining manufacturing capability, directly addressing the loss of substance issue.
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 enables the efficient formation of ceramic objects without additional support members, reduces toxic emissions, simplifies the cleaning process, and allows for the recycling of the slurry, resulting in a safer, more environmentally friendly, and cost-effective manufacturing process.
Implementation Method 1
a step Sd of irradiating light beam to the reaction layer by using one of the plurality of projected slice graphics, so that the slurry on the reaction layer is cured by the irradiation of the light beam
Data Source
AI summary
The invention relates to a water-based ceramic three-dimensional laminate material and a method for using the same material to manufacture the ceramic objects, comprising: a step Sa of preparing a plurality of projected slice graphics and a slurry, wherein the projected slice graphics are formed by slicing a three-dimensional image along a specific direction with a specific thickness, the slurry is prepared by mixing the material powder, the photo-curing resin, the solvent and the additive; a step Sb of uniformly laying the slurry on the substrate to form a sacrificial layer; and a step Sc of uniformly laying the slurry on the slurry to form a reaction layer on the sacrificial layer; a step Sd of irradiating the reaction layer with a light beam according to one of the plurality of projected slice graphics, and the slurry is cured after being irradiated; a step Se of repeating steps Sc and Sd until a ceramic body is formed; a step Sf of washing the ceramic body with water or an organic solvent; and a step Sg of sintering the ceramic body at a high temperature to form a ceramic object.