The effect of particle size distribution on the microstructure and properties of Al2O3 ceramics formed by stereolithography

Stereolithography (SL) shows advantages for preparing alumina-based ceramics with complex structures. The effects of the particle size distribution, which strongly influence the sintering properties in ceramic SL, have not been systematically explored until now. Herein, the influence of the particle size distribution on SL-manufactured alumina ceramics was investigated, including bending strength at room temperature, post-sintering shrinkage, porosity, and microstructural morphology. Seven particle size distributions of alumina ceramics were studied (in μm/μm: 30/5, 20/3, 10/2, 5/2, 5/0.8, 3/0.5, and 2/0.3); a coarse:fine particle ratio of 6:4 was maintained. At the same sintering temperature, the degree of sintering was greater for finer particle sizes. The particle size distribution had a larger influence on flexural strength, porosity and shrinkage than sintering temperature when the particle size distribution difference reached 10-fold but was weaker for 10 μm/2 μm, 5 μm/2 μm and 5 μm/0.8 μm. The sintering shrinkage characteristics of cuboid samples with different particle sizes were studied. The use of coarse particles influenced the accuracy of small-scale samples. When the particle size was comparable to the sample width, such as 30 μm/5 μm and 5 mm, the width shrinkage was consistent with the height shrinkage. When the particle size was much smaller than the sample width, such as 2 μm/0.3 μm and 5 mm, the width shrinkage was consistent with the length shrinkage. The results of this study provide meaningful guidance for future research on applications of SL and precise control of alumina ceramics through particle gradation.     

Development of silica based organic slurries for stereolithographic printing process

In this study, silica based slurries for stereolithographic printing of glass structures are developed and characterized. Stereolithography has the potential to print complex structures with high resolution. Therefore, acrylate based photocurable slurries have been developed and their viscosities are examined as a function of the solid loading. A critical shear rate can be derived, which must not be exceeded during the printing process. Therefore, rheological characterizations provide important insights into the printing process and the ability to produce samples with precise structures. Other properties such as polymerization time and curability kinetic were investigated with time dependent attenuated total reflection infrared spectroscopy (ATR-IR). Afterwards, the slurries were printed on a commercial printer operating with visible light. For debinding the printed green bodies, the decomposition temperatures were derived from thermogravimetric analysis in order to obtain stable and transparent samples.     

The structure of parts produced by stereolithography injection mould tools and the effect on part shrinkage

Stereolithography (SL) tooling for plastic injection moulding provides a low cost and quick alternative to hard tooling methods when producing a small quantity of parts. However, work by the authors has shown that a different rate of polymer shrinkage was experienced in semi-crystalline parts when produced from SL moulds as compared to those from conventional metal tooling methods. Different shrinkage means the parts are not truly the same as those that would be produced by metal tooling and highlights a disadvantage to SL tooling.This work associates the increased shrinkage experienced to a greater percentage crystallinity developed in the parts due to their thermal history during processing. In these experiments the cooling rate, which is imparted due to the heat transfer characteristics of the mould has been identified as the controlling factor of a parts % crystalline content and the cause of shrinkage anomalies.The morphology analysis results show that there is 30% more crystallinity developed in the nylon (PA66) parts produced in SL moulds than those produced from aluminium moulds. The results also reveal different characteristics during thermal analysis that may also be due to the thermal history imparted by the mould.The work utilises the thermal analysis technique differential scanning calorimetry (DSC) to quantify the different levels of crystallinity in the parts. The thermal characteristics of the mould are demonstrated by real-time data acquisition.     

Structure-property relationship of nano enhanced stereolithography resin for desktop SLA 3D printer

Organically modified nanofillers, including nano SiO₂, montmorillonite and attapulgite were loaded to stereolithography resin (SLR). The surface of nanofillers were modified using organic modifier of 3-(trimethoxysilyl)propyl methacrylate (γ-MPS) and (1-hexadecyl)dimethyl allyl ammonium chloride (C₁₆-DMAAC), and were characterized by FTIR and small angle XRD analysis. The morphology of nanocomposites were observed by TEM. Viscosity and curing speed of SLR nanocomposites at increasing nanofillers loading were also studied. The mechanical properties of printed samples fabricated by a home-made stereolithography apparatus (SLA) 3D printer were tested. The influence of nanoparticles on the accuracy was measured and discussed. It was found that addition of 5% w/w of nano SiO₂ increased the tensile strength and modulus by 20.6% and 65.1% respectively, and the printed accuracy was not significantly influenced. This study opens the way to the application of nanocomposites in the desktop level SLA 3D printing.     

Fabrication and properties of diatomite ceramics with hierarchical pores based on direct stereolithography

Porous diatomite ceramics with hierarchical pores and high apparent porosity (50.29–56%) were successfully fabricated via direct stereolithography. The pre-ball-milling time, dispersant type and dispersant concentration were systematically investigated to prepare diatomite pastes with high solid loading, low viscosity and a self-supporting effect. The results showed that a pre-ball-milling time of 24 h was more suitable to prepare diatomite pastes with high solid loading, and Span80 at 2 wt% was the optimal dispersant to obtain 40 vol% diatomite paste with a low viscosity and a self-supporting effect. To restrain the formation of defects, a heating rate as low as 0.2 °C/min was allowed to control the pyrolysis rate in the multistage debinding process. At sintering temperatures ranging from 900 °C to 1000 °C, porous diatomite ceramics exhibited a typical bimodal porosity, high apparent porosity and great flexural strength.     

Fabrication of cancellous-bone-mimicking β-tricalcium phosphate bioceramic scaffolds with tunable architecture and mechanical strength by stereolithography 3D printing

It is highly challenging to fabricate bioceramic scaffolds mimicking architecture and mechanical strength of cancellous bone. Gyroid structure, which is based on triply periodic minimal surface, highly resembles the architecture of cancellous bone. Herein, β-tricalcium phosphate (β-TCP) bioceramic scaffolds with gyroid structure were fabricated by stereolithography (SLA) 3D printing. The SLA 3D printing ensured high precision of ceramic part. The porosity (51–87%), pore size (250 – 2400 µm), pore wall thickness (< 300 µm) and compressive strength (0.6 – 16.8 MPa) of gyroid bioceramic scaffolds were readily adjusted to match various sites of cancellous bone. The gyroid bioceramic scaffolds were more favorable for cell proliferation than the grid-like bioceramic scaffolds. The cancellous-bone-mimicking gyroid bioceramic scaffolds with tunable architecture and mechanical strength were expected to efficiently repair the target bone defects.     

紫外光固化快速成形中提高加工效率的方法

光固化成形是一种基于逐层累加方式发展起来的新的制作工艺,零件的加工效率是成形中需要考虑的关键问题之一。本文分析了影响加工效率的三个因素,即扫描参数、制作方向和扫描方向,并通过实验证明了优化制作工艺能够显著提高零件的制作效率。     

基于CAD和SL的人工骨微管支架的制备研究

研究一种基于光固化快速成形技术的人工骨支架制备方法。设计空间结构的人工骨支架负型,利用立体光固化快速成形系统制造人工骨支架负型树脂原型,在人工骨支架负型树脂原型中填充β-磷酸三钙,通过热分解的方法去除SL原型,获得生物活性人工骨支架。研究了烧结与去除原型的方法,测得人工骨支架表面粗糙度分别是Ra=3.69,有利于细胞的黏附。进行体外细胞培养研究,发现成骨细胞能够在这人工骨支架上黏附生长,并向微管内生长,具有良好的生物学特性。     

Stereolithographical fabrication of dense Si3N4 ceramics by slurry optimization and pressure sintering

Photocurable gray-colored Si₃N₄ ceramic slurry with high solid loading, suitable viscosity and high curing depth is critical to fabricate dense ceramic parts with complex shape and high surface precision by stereolithography technology. In the present study, Si₃N₄ ceramic slurry with suitable viscosity, high solid loading (45 vol %) and curing depth of 50 μm was prepared successfully when surface modifier KH560 (1 wt%) and dispersant Darvan (1 wt%) were used. The slurry exhibits the shear thinning behavior. Based on the Beer-Lambert formula, D_p (the attenuation length) and E_c (the critical energy dose) of Si₃N₄ ceramic slurry with solid loading of 45 vol % were derived as 0.032 mm and 0.177 mJ/mm², respectively. Si₃N₄ ceramic green parts with complex shape and high surface precision were successfully fabricated by stereolithography technology. After optimizing the debinding and sintering process for green parts, dense Si₃N₄ ceramics with 3.28 g/cm³ sintering density were fabricated. The microhardness and fracture toughness of as-sintered Si₃N₄ ceramics are ~14.63 GPa and ~5.82 MPa m^1/2, respectively, which are comparable to those of the samples by traditional dry-pressed and pressureless sintering technology. These results show that ceramic stereolithography technology could be promising to fabricate high performance ceramics, especially for gray-colored monolithic Si₃N₄ ceramics.     

光固化3D打印离型膜在树脂作用下的变形分析

在光固化光敏树脂成型过程中,聚四氟乙烯离型膜会在树脂液位的波动影响下发生变形,进而影响光固化制件的精度,因此需要减小离型膜在制件过程的变形量,确保其相对稳定。首先分析树脂液位变化,通过液位变化量,等效出树脂液波动带给离型膜的载荷,建立离型膜受力模型。然后基于离型薄膜的挠度变形理论,应用Ansys软件进行模拟研究,对不施加预应力和施加不同预应力作用下的离型膜变形结果分析,结果表明施加预应力有利于提高离型膜稳定性,且施加预应力为2. 645M Pa时离型膜受到树脂波动影响最小,位置精度变化在0. 01 mm。