Project 10

Additive Manufacturing of High-Loading Ceramic-Polymer Composites Using Paste Extrusion 3D Printing

(Dr. Kunal Kate, ME)

The project aims to revolutionize orthopedic implant manufacturing by addressing the limitations of conventional methods in replicating the structural and mechanical properties of human bone. Mismatched properties often lead to complications such as inflammation and instability during implant integration [1, 2]. To overcome these challenges, the project proposes the utilization of 3D printing technology to create implants with customized structures and mechanical attributes that closely emulate natural bone characteristics. However, current methods, particularly the bound ceramic material extrusion (MEX) 3D printing using filaments, are hindered by filament brittleness, resulting in compromised 3D printing and the ensuing implant properties [1-3]. The project's core objective is to overcome these limitations by leveraging the MEX process for additive manufacturing of ceramic-polymer composites. Specifically, the focus is on the development of a groundbreaking paste-based extrusion 3D printing approach. This innovative methodology aims to achieve high ceramic loading levels (70-80%) in the composite material. A key feature of the approach involves the strategic utilization of Infrared (IR) radiation exposure to facilitate layer-by-layer printing (Image 1). This ensures the creation of intricate 3D structures while maintaining sufficient green strength, an essential requirement for successful implant integration.

As part of the project, the REU student will be trained to perform a variety of experiments and analyses. Firstly, develop engineering designs for 3D architectures/implants or acquire 3D scanned data for conversion to printable files. Secondly, formulate an IR-dryable ceramic-polymer paste and assess viscosity and extrusion flowability. Thirdly, conduct Thermogravimetric Analysis (TGA) to determine optimal sintering conditions based on paste material properties. Fourthly, optimize 3D printing parameters such as nozzle diameter, layer height, extrusion pressure, and print speed. To do this, the REU student will learn and characterize the materials to establish relationships between viscosity, extrusion pressure, and in-fill quality for improved printability. Fifthly, perform debinding and sintering to obtain ceramic parts. Lastly, the REU student will establish Process-Structure-Property (PSP) correlations to understand the relationship between manufacturing parameters, microstructure, and material properties by performing mechanical testing and Scanning Electron Microscopy (SEM) to visualize grain structures and defects.

Overall, the project endeavors to advance additive manufacturing of highly loaded ceramic-polymer composites by introducing a paste-based extrusion 3D printing technique. By systematically addressing each experimental objective, the research aims to achieve enhanced material properties, print quality, and mechanical performance, contributing to the broader field of ceramic-metal additive manufacturing applications.

References:

[1]        K. Sudan, P. Singh, A. Gökçe, V. K. Balla, and K. H. Kate, "Processing of hydroxyapatite and its composites using ceramic fused filament fabrication (CF3)," Ceramics International, vol. 46, no. 15, pp. 23922-23931, 2020, doi: 10.1016/j.ceramint.2020.06.168.

[2]        P. Singh, V. K. Balla, A. Tofangchi, S. V. Atre, and K. H. Kate, "Printability studies of Ti-6Al-4V by metal fused filament fabrication (MF3)," International Journal of Refractory Metals and Hard Materials, vol. 91, 2020, doi: 10.1016/j.ijrmhm.2020.105249.

[3]        N. Wright, P. Singh, S. Park, R.-H. Song, and K. Kate, "Ceramic Fused Filament Fabrication (CF3) 3D Printing of NiO-YSZ Structures for Solid Oxide Fuel Cells," presented at the Materials Science & Technology, 2019, Paper presented at MS&T19, Portland, Oregon, USA, 2019.