Dimensional retention of photocured ceramic units during 3D printing and sintering processes

In this study, photocuring-based digital light processing (DLP) 3D-printing technology was used to prepare basic photocuring units from cordierite ceramic slurries loaded with three different average particle sizes. Exposure time was varied to realize a range of ultraviolet light-energy dosages. Basic units, including single lines, apertures, and single walls, were printed with different feature dimensions such as single-line width and thickness, aperture diameter, and single-wall thickness. The morphologies and structures of the units were studied after printing and sintering. Their dimensions were measured, and the relative and absolute differences before and after each processing step were calculated. The dimension-retention levels were finally determined and analyzed across the ranges of slurries, exposure times, and designed dimensions. Detailed insights into the printing and sintering behaviors and performances of the ceramic slurries and printed units were gained. This study contributes to the understanding and analysis of potential dimensional errors and the printed and sintered quality of ceramic components prepared based on photocuring-based DLP 3D printing.     

Development and characterization of inks for screen printing of glass solders for SOFCs

Glass ceramics are supposed to produce stable sealants between ceramic electrolyte and ferritic steel in planar SOFC stacks. The screen printing method is a suitable industrial process in order to produce layers with tailored height and width reproducibly. An appropriate suspension was developed for this application and improved by adjusting the additive composition. This study investigates the rheological behavior of screen printing inks and the corresponding topography of the printed layers. Rotary measurements were carried out to analyse the impact of shear rates on viscosity showing shear thinning behavior. In addition, oscillatory rheometry is performed to gain information about the viscoelastic properties of the slurries and to understand the internal structure of the developed inks. The viscoelasticity and the recovery behavior after shear loading are crucial for the topography of printed films. The principal investigations are executed on solvent-based suspensions, whereby the knowledge gained is used for a transfer to water-based systems allowing a more environmentally friendly handling.     

Preparation and mechanical performance of SiCw/geopolymer composites through direct ink writing

Traditional geopolymer structures benefit from the durability, irradiation resistance, and environmental friendliness, but their brittleness limits their applications where repeated, impactive strains are imparted. This situation may be alleviated if complex structures with tunable geometry can be fabricated, for example, through 3D printing based on direct ink writing (DIW). In this research, SiC whisker/geopolymer (SiC_w/GP) composites were fabricated by the DIW for the first time. The rheological behaviors of the SiC_w/GP inks and the fracture behaviors of the printed samples were explored. The modified printing inks exhibited non-Newtonian fluid behavior (shear-thinning). Subsequently, a series of lightweight architected structures were fabricated, and they revealed how reinforcement and architecture of the printed structures could influence both the strength and toughness of the SiC_w/GP composites.     

Digital printing of acrylic fabric with cationic dyes using conventional inkjet printer

A special printing ink formulation based on cationic dyes is developed for digital printing of acrylic fabrics using a conventional inkjet printer. In order to investigate the contribution of color gamut boundary of printer colorants to printing efficiency, customized color targets containing 3164 color patches in 25 different hues were generated. The printed color patches were then fixed through steaming for 30 minutes followed by washing with hot soap and water and finally drying. To show the influence of dye fixation on colorimetric changes as well as color gamut boundary of samples, the L*a*b* values of color patches before and after fixation process were compared. Results demonstrate that color saturation of samples is enhanced dramatically after the dye fixation process. In fact, 3D color gamut of color patches has been drastically expanded as a direct consequence of adsorption to absorption transition. Additionally, dye fixation changes the structure of printed image from halftone superimposed dots to contone superimposed dyes. Strictly speaking, during fixation process, colors inside the halftone dots diffuse through the interfacial area to make the individual printed dots integrated. This is in analogy to the chromogenic photography films and dye‐sublimation thermal transfer processes by which contone images are produced. Moreover, dye fixation improves the washing fastness of digitally printed acrylic fabrics to the level comparable with the traditional screen printing method. © 2016 Wiley Periodicals, Inc. Col Res Appl, 42, 244–249, 2017     

3D printing dielectric elastomers for advanced functional structures: A mini-review

Three-dimensional (3D) printed bionic products play an important role in intelligent robotics, microelectronics, and polymers. The printing and manufacturing process of 3D printers is conducive to obtaining soft structures that meet specific requirements, and saves time and cost. Soft intelligent robotics, an emerging research field, has always been developed based on soft materials and actuators with their biological properties. This article reviews the current understanding of 3D bioprinting technologies for dielectric elastomers (DEs), DE actuators (DEAs) and soft robots, such as inkjet, extrusion, laser-induced and stereolithography bioprinting. 3D printers for fabricating soft materials are presented and classified. The approaches to exploit 3D bioprinters for DEs/DEAs are as follows: (1) 3D printing DEAs utilize ionic hydrogel–elastomer hybrids that are analogous to human muscles, and the DEAs usually have flexible structures and large deformations with multiple functionalities. (2) An electrohydrodynamic (EHD) 3D printer confers high printing resolution and high production efficiency, which offers advantages such as full automation and flexible design. The optimal printing conditions are mainly determined by the effects of printing voltages and ink properties, which are related to the formation of the liquid cone and the printed line width. Furthermore, the advantages of 3D bioprinting technologies have accelerated their development and applications.     

Printing cotton fabrics with reactive dyes of high reactivity from an acidic printing paste

The behaviour of reactive dyes of high reactivity during the printing process of 100% cotton fabrics from an alkaline and acidic printing paste was studied in detail. The printing pastes were stored for different periods of time and then the fabrics were printed. The samples were subjected to two methods of fixation, the first by steaming and the second by thermofixation. The effects of different factors such as alkali and acid concentration, storage time of the printing pastes and method of fixation on the K/S values of the prints were investigated. The fastness properties of the printed areas were also measured to determine the improvement obtained by acidic printing with high-reactivity reactive dyes on cotton fabrics.     

Nanogrooved carbon microtubes for wet three‐dimensional printing of conductive composite structures

Recent advances in three‐dimensional (3D) printing have enabled the fabrication of interesting structures which are not achievable using traditional fabrication approaches. The 3D printing of carbon microtube composite inks allows fabrication of conductive structures for practical applications in soft robotics and tissue engineering. However, it is challenging to achieve 3D printed structures from solution‐based composite inks, which requires an additional process to solidify the ink. Here, we introduce a wet 3D printing technique which uses a coagulation bath to fabricate carbon microtube composite structures. We show that through a facile nanogrooving approach which introduces cavitation and channels on carbon microtubes, enhanced interfacial interactions with a chitosan polymer matrix are achieved. Consequently, the mechanical properties of the 3D printed composites improve when nanogrooved carbon microtubes are used, compared to untreated microtubes. We show that by carefully controlling the coagulation bath, extrusion pressure, printing distance and printed line distance, we can 3D print composite lattices which are composed of well‐defined and separated printed lines. The conductive composite 3D structures with highly customised design presented in this work provide a suitable platform for applications ranging from soft robotics to smart tissue engineering scaffolds. © 2019 Society of Chemical Industry     

UV‐assisted screen‐printing of flat textiles

An approach to printing of flat textiles is presented in this work. A screen‐printing method was applied on a cotton fabric. An aqueous printing paste was prepared from thickening and crosslinking agents and an ultraviolet‐sensitive tetrazole ring‐based compound of 2,3,5‐triphenyltetrazolium chloride or nitrotetrazolium blue chloride. After the printing process, a pattern was just visible with the naked eye. The development of colour occurred after exposure of the textile to ultraviolet light of 253.7 nm and was caused by the transformation of 2,3,5‐triphenyltetrazolium chloride or nitrotetrazolium blue chloride salts into the corresponding formazans, which are insoluble in water. The printed designs were resistant to washing. The stability of the colour of the samples is discussed in the case of prolonged irradiation, both with ultraviolet light of 253.7 nm and with daylight. This method of printing is a recent proposition for creative textile designing. It also seems to indicate a likely type of dye that may be further developed as potentially attractive for ultraviolet‐assisted printing or dyeing of textiles.     

3D-printed polymer packing structures: Uniformity of morphology and mechanical properties via microprocessing conditions

Three-dimensional (3D) printing is an attractive approach to fabricate highly porous extremely lightweight structures for architecture antivibrational packaging. We report 3D printing processing of model packaging structures using biodegradable poly(lactic acid) (PLA) as a source material, with acrylonitrile butadiene styrene (ABS) utilized as a common 3D printing source material as a traditional benchmarked material. The effects of printing temperature, speed, and layer morphology on the layer-by-layer 3D-printed structures and their mechanical properties were considered. Three different characteristic morphologies were identified based on printing temperature; the microscopic surface roughness was dependent on the printing speed and layer height. We demonstrate that the mechanical performances and surface properties of 3D-printed PLA structures could be improved by optimization of printing conditions. Specifically, we evaluate that these PLA-based 3D structures printed exhibited better surface qualities and enhanced mechanical performance than traditional ABS-based structures. Results showed that the PLA-based 3D structures possessed the favorable mechanical performance with 34% higher Young's modulus and 23% higher tensile strength in comparison to the ABS-based 3D structures. This study provides guidelines for achieving high-quality 3D-printed lightweight structures, including smooth surfaces and durable mechanical properties, and serves as a framework to create biodegradable 3D-printed parts for human use.     

Visible‐near infrared concealment of cotton/nylon fabrics using colored pigments and multiwalled carbon nanotube particles (MWCNTs)

To match the reflectance profile of desert colors including dark brown, light brown and olive green in the visible‐near IR (Vis‐NIR) bands, five selected colored pigments were utilized to print woven cotton/nylon fabrics. Multi‐walled carbon nanotube particles (MWCNT's) were also added to some of the printing pastes. The reflectance of printed fabrics was evaluated by using spectrophotometric technique. The effect of adding MWCNT's, on washing; light and crocking fastness alongside with colorimetric values of printed samples was evaluated. Furthermore, the water absorption time was measured in order to determine wettability of each printed sample. The results demonstrated that the presence of MWCNT's in concentration range of 0.04–0.12 g kg^?1 in printing formulations was found to cause considerable decline in Near Infrared (NIR) reflectance while a surprising increase in visible reflectance of samples was observed. Color characteristics of printed fabrics were noticeably changed even at concentrations as low as 0.12 g kg^?1 MWCNTs in printing formulations. Presence of MWCNTs in printing formulations was found to cause a significant increase in wetting time of samples. Also, the results indicated that air permeability of printed samples containing MWCNT's were higher than samples printed with no MWCNTs. Phenomena imposed by MWCNT's presence on pigment printed samples showed very good fastness levels in crocking, washing and light fastness tests. In dark brown sample, adding MWCNTs to the pigment printing pastes could tune the overall reflectance in order to match the standard reflectance profile accepted for use in concealment color of desert areas. © 2013 Wiley Periodicals, Inc. Col Res Appl, 40, 93–98, 2015     

打印温度对3D打印用黄芪药渣/聚乳酸材料性能的影响

为了探究黄芪药渣/聚乳酸(APS/PLA)材料3D打印过程中打印温度参数对产品性能的影响,以熔融挤出法制备了黄芪药渣/聚乳酸复合材料(APS/PLA-CM)线材,采用熔融沉积成型(FDM)-3D打印工艺打印试样,研究了打印温度对复合材料力学性能及热性能的影响.通过力学测试及扫描电子显微镜(S EM)观察层间结合情况发现...     

Digital light processing additive manufacturing of in situ mullite-zirconia composites

Digital light processing (DLP) can produce small series ceramic parts with complex geometries and tiny structures without the high cost of molds usually associated with traditional ceramic processing. However, the availability of feedstock of different ceramics for the technique is still limited. Mullite-zirconia composites are refractory materials with diverse applications, nevertheless, their 3D printing has never been reported. In this work, alumina and zircon were used as raw materials for additive manufacturing by DLP followed by in situ mullite and zirconia formation. Thus, coarse zircon powder was milled to submicrometric size, alumina-zircon photosensitive slurries were prepared and characterized, parts were manufactured in a commercial DLP 3D printer, debound, and sintered at different temperatures. The printed parts sintered at 1600 °C completed the reaction sintering and reached a flexural strength of 84 ± 13 MPa. The process proved capable of producing detailed parts that would be unfeasible by other manufacturing methods.     

Robocasting of reaction bonded silicon carbide structures

A novel shaping method for the fabrication of reaction bonded silicon carbide structures was investigated in this work. A paste consisting of silicon carbide as inert filler and carbon powder was developed and printed by robocasting technology. Layer by layer deposition of the ceramic paste facilitates the printing of complex shaped structures. Different structures such as lattices, hollow cylinders, bending bars and gyroids were printed using nozzles with diameter of 0.5 mm and 1.5 mm. After pyrolysis at 700 °C and further heat treatment at 1850 °C the samples were infiltrated using the liquid silicon infiltration technique to obtain dense near-net shape RBSC structures. The robocasted structures showed a hardness of approximately 20 GPa, a thermal conductivity of ～112 W/m*K, Young’s modulus of ～356 GPa, flexural strength of ～224 MPa and an amount of residual silicon of approximately 23%. These measured properties are comparable with those of traditionally fabricated RBSC.     

Optimisation of process parameters of Alpaca wool printing with Juglans regia natural dye

The aim of this research study was to optimise the process parameters of Alpaca wool hand‐knitted samples screen‐printing with Juglans regia natural dye and to set the optimal conditions regarding colour yield, colour fastness and colouristic properties of printed samples. An extensive preliminary examination of the Alpaca woollen yarn and hand‐knitted samples characteristics, the characteristics of suitable thickeners and the optimisation of the printing paste composition, was performed. A starch‐based thickener, British Gum, with a dry matter content of 4% was selected due to its rheological properties responding to properties of the Alpaca yarn and knitwear. It was determined that the fluidity increases while the viscosity and the elasticity decrease in acidic pH, so a pH of 4 was set for the thickener preparation. The thickener of lower viscosity and higher fluidity assures easier pressing of printing paste through the screen, giving uniform colour yield on the substrate, contributing to easier absorption of dyes into the fibre. A 45‐minute fixing process at 105°C by steaming delivered the best results of printing quality. Iron sulphate was used as the mordanting agent. The colour fastness to washing, dry and wet rubbing, and to light, was tested for samples with and without mordanting. The highest light and washing fastness were obtained with the iron sulphate mordanting agent printed in acid (pH 4) with paste containing 4% dry matter‐based thickener. The rubbing fastness was satisfactory for samples with iron sulphate printed with paste containing 4% dry matter thickener, fixed for 45 minutes, regardless of the pH.     

Additive manufacturing of bioceramic scaffolds by combination of FDM and slip casting

Bioceramic scaffolds consisting of bioactive glasses or calcium phosphates have a high biocompatibility and are able to stimulate the ingrowth and regeneration of bone. For the production of these complex, highly porous structures, the additive manufacturing technologies are of particular importance. Normally, the image of the CAD model is printed directly. In this study, the indirect approach was chosen. The Fused Deposition Modeling (FDM) process was used to print thermoplastic molds, which were the negative of the ceramic to be produced. Subsequently, these molds were filled with ceramic slurries as in the slip casting process and the thermoplastic form was burnt out. The viscosity of the slurries as well as the thermal behaviour of the green bodies was characterized. The resulting bioceramic scaffolds have a filigree structure with moderate porosity. The compressive strength of these components is above the strength of cancellous bone.     

Effect of layer printing delay on mechanical properties and dimensional accuracy of 3D printed porous prototypes in bone tissue engineering

Recent advancements in computational design and additive manufacturing have enabled the fabrication of 3D prototypes with controlled architecture resembling the natural bone. Powder-based three-dimensional printing (3DP) is a versatile method for production of synthetic scaffolds using sequential layering process. The quality of 3D printed products by this method is controlled by the optimal build parameters. In this study, Calcium Sulfate based powders were used for porous scaffolds fabrication. The X-direction printed scaffolds with a pore size of 0.8 mm and a layer thickness of 0.1125 mm were subjected to the depowdering step. The effects of four layer printing delays of 50, 100, 300 and 500 ms on the physical and mechanical properties of printed scaffolds were investigated. The compressive strength, toughness and tangent modulus of samples printed with a delay of 300 ms were observed to be higher than other samples. Furthermore, the results of SEM and μCT analyses showed that samples printed with a delay of 300 ms have higher dimensional accuracy and are significantly closer to CAD software based designs with predefined 0.8 mm macro-pore and 0.6 mm strut size.     

Rheological Control of the Coffee Stain Effect for Inkjet Printing of Ceramics

The rheology of inkjet printing inks must be well controlled in order to be able to form small droplets. One solution is to use low volume fraction dispersed suspensions, but this leads to a common problem during drying called the coffee stain effect. It is caused by particle migration from the center to the edge of a drying drop and leads to nonuniform printed structures. This article describes an approach, to suppress the coffee stain effect by a sufficiently fast increase in viscosity after deposition. Due to the viscosity limitations during printing, inks with tailored rheology and drying behavior need to be developed. Ceramic inks were prepared and printed. First, a binder was added to study the influence of viscosity on printability and the coffee stain effect. Second, the use of a high vapor pressure solvent for faster drying was investigated. Eventually, an ink with the combination of binder and fast drying agent was prepared. This ink showed a considerable decrease in drying time as well as a rapid increase in viscosity after deposition and was suitable to completely suppress the coffee stain effect. Plateau‐like structures were achieved by adapting the drying temperature to permit particle movement to a certain degree.     

Preparation of high solid loading and low viscosity ceramic slurries for photopolymerization-based 3D printing

In this study, high solid loading and low viscosity cordierite slurries are successfully developed for the first time for photopolymerization-based additive manufacturing. The processability of the slurries is mainly determined by their rheological properties and photocuring parameters. The slurry preparation involves the orthogonal optimization of compositions in order to achieve suitable viscosity, stability and homogeneity. The photocuring parameters of the as-prepared slurries, including penetration depth D_p and critical exposure E_c, are also determined experimentally. Results show that viscosity increases with reduction in particle size. A higher solid-volume fraction also results in an exponential growth in viscosity. As for the dispersant amount, a concentration of 5?wt% leads to the lowest viscosity. Particle size also play an important role in the solid loading capacity of the slurries, as results suggest that smaller particles improve performance. In terms of the photocuring behaviors, the addition of 2?wt% photoinitiator generates an optimal curing process. 40?vol% solid loading leads to the thickest curing depth for all slurries with different types of particle sizes. Finally, a cordierite part with a complex hollow structure and a fine resolution is successfully fabricated. The present study offers a material basis for the polymerization-based 3D printing of porous cordierite structures.     

Scientific Aspects of Transfer Printing

The mechanism of vapour phase transfer printing is described on the basis that the process involves a 3-phase system consisting of a printed dye layer separated from a fabric by air space. The behaviour of dye in each phase under transfer printing conditions is examined and recent experimental results on differential air flow and permeability of printed paper are described. Finally the development of disperse and other dye structures for specific use in transfer printing is reviewed.     

Additive manufacturing of barium titanate based ceramic heaters with positive temperature coefficient of resistance (PTCR)

Lanthanum/manganese doped barium titanate (BT) based PTCR functional heater elements/structures were fabricated with desirable electrical properties for the first time using Additive Manufacturing (AM). 3D printed components of varying size and shape and prototype honeycomb lattices with high density were achieved through AM. Aqueous, less organic containing (2.5 wt% additives versus 10–30 wt% added typically), eco-friendly ink formulations were developed with suitable rheological properties for 3D printing. For BT prints, the sintered densities of the 3D ceramic parts were found to be >99% TD, highest reported value so far. The microstructure, electrical properties and heating characteristics of the printed PTCR components were studied in detail and their thermal stability evaluated using infrared imaging and benchmarked against commercial PTCR heating element. The heating behaviour of the solid and porous 3D printed components was demonstrated to be similar, paving the way for light weight (?47% reduction in weight) heaters suitable for automotive/aerospace applications and less materials wastage during device fabrication.