Robotic deposition of 3d nanocomposite and ceramic fiber architectures via UV curable colloidal inks

A novel approach for producing predetermined, complex 3d ceramic architectures by robotic deposition where UV radiation is used for solidification is presented. Homogeneous, highly loaded, solvent free colloidal inks with controlled viscoelastic properties are achieved by proper selection of monomers and surfactants. Room temperature deposition of complex 3d fiber networks having filaments in the 100 μm range is demonstrated for Al₂O₃ and hydroxyapatite model particles for structural and biomedical applications. Solidification of the structures by UV radiation allows additional shaping of the structures by post-printing processes such as cutting, folding and bonding. 2d and 3d architectures with high aspect ratios retain their shape and transform to macroscopic ceramics after thermal debinding and sintering procedures. Sintered alumina fiber networks functionalized with a 3-5 μm layer of TiO₂ nanoparticles exhibit photocatalytic activity for the decomposition of formaldehyde as a similar weight of loose powder, indicating possible applications in catalytic reactors prototypes.