3D printing technology, also known as augmented material manufacturing, has the advantages of simple operation, rapid molding speed and high precision. With the continuous development of 3D printing technology, it has been gradually applied to various fields of the manufacturing industry. Compared with the traditional preparation process, 3D printing ceramic materials and advanced sintering technology can significantly reduce the processing cost, shorten the production cycle and save raw materials. The development potential of 3D printing ceramic technology is huge, which will promote the development of aerospace, medicine and industry. It is widely applied in other fields.
Overview of 3D printing ceramic technology
At present, 3D printing ceramic technology mainly includes inkjet printing technology, melting deposition molding technology, laser curing molding technology, layered solid manufacturing technology and laser selective sintering technology. These technologies can be classified according to different standards. Among them, the methods based on laser forming are light curing forming technology, layered solid manufacturing technology and laser selective sintering technology, and the other two are non-laser forming methods. Melting deposition molding and laser selective sintering technology are needed to set up supporting structures, while the other three do not need supporting structures. Finally, according to the process can be divided into direct molding method and layer-by-layer bonding method, inkjet printing technology is to mix ceramic powder and binder to prepare ceramic ink, through 3D printing direct molding, belongs to direct molding method, the other four technologies belong to layer-by-layer bonding method.
1. Inkjet printing technology
The working principle of 3D inkjet printing ceramic technology is that the ceramic ink in the capillary tube at the bottom of the nozzle is rapidly vaporized by heating the nozzle and bubbles are formed and expanded rapidly in a very short time. As the bubbles expand to a critical value to overcome the surface tension of the ink, the ink sprays from the top of the nozzle capillary. Ceramic ink draws patterns according to the pre-modeled data of the computer, and realizes the 3D printing process by stacking them. When the heating stops, the ink cools, the bubbles begin to condense and contract, the ceramic ink retracts, and the ceramic ink stops being supplied.
The advantages of 3D inkjet printing ceramics technology are: users design personalized ceramics according to their needs, the cost is greatly reduced, to a large extent, saving manpower and material resources, while the technology does not need the assistance of laser technology, has been widely developed and applied in daily life.
2. Melt deposition molding technology
Melting deposition molding technology is composed of three components: feeding roll, guide sleeve and sprinkler head. Its process engineering is that hot-melting filamentous material passes through feeding roll, enters guide sleeve with the cooperation of driven and active roll, and uses the low friction property of guide sleeve to make filamentous material enter the sprinkler accurately and continuously. The material is heated and melted in the sprinkler head, and 3D printing is done according to the original shape required.
The advantages of melt deposition molding technology are that it does not need the assistance of laser technology, the cost is lower, and the later maintenance is more convenient. However, the technology needs to set up supporting structure to ensure that the ceramic parts will not collapse in the printing process.
At present, there are two kinds of supporting materials: one is peeling supporting materials, which need manual peeling in the later treatment, and the other is water-soluble supporting materials, which can be removed conveniently and quickly by physical or chemical methods in the later treatment. Therefore, the latter is widely used in the market as a supporting material, to a certain extent, reducing the complexity of the post-treatment process.
3, laser curing molding technology
The basic principle of laser curing technology is to focus the ceramic-photosensitive resin mixture liquid in the working tank through the ultraviolet laser beam, according to the designed cross-section of the original layer, and curing point by point, from point to line, from line to surface. After curing the surface in the X-Y direction, the three-dimensional printing ceramic material is finished by the movement of the elevator in the z-axis direction.
The advantages of laser curing technology are: it is suitable for making parts with complex structure and high accuracy. It can be operated online, and remote control is conducive to full automation of production. In addition, the technology does not need to be sintered, and does not need to add sintering aids, so it can be completed at lower temperatures and pressures.
The shortcomings are: the working environment conditions are demanding, low efficiency, need to set up support structure, process is more complex.
4. Layered solid manufacturing technology
Laminated solid manufacturing technology is a thin sheet material superposition process. The process is to cut thin film materials directly by laser, move the lifting table, cut a new layer of thin film materials superimposed on the previous layer of materials, bond forming under the action of hot-bonded components, to achieve the transformation from layer to solid. In 3D ceramic printing, ceramic sheet materials for layered solid manufacturing can be prepared by tape casting.
The advantage of layered solid manufacturing technology is that the molding speed is fast and it is suitable for manufacturing laminated complex structural parts. The disadvantage is that the technology is not suitable for printing complex and hollow parts, there is a more obvious step effect between the layers, and the final product boundary needs to be polished and polished.
5. Laser selective sintering technology
Laser selective sintering technology is mainly realized by the combination of three structural components: roller, laser and worktable. The concrete principle is that the powder is laid on the worktable by the roller, the powder is scanned by the laser beam controlled by the computer, and the binder in the powder is melted by the laser scanning to form the layered structure. After the scanning, the worktable drops, the rollers are coated with a new layer of powder, and the rollers are re-scanned by laser. The worktable is bonded to the solidified sheet ceramics of the previous layer, and the finished product is printed after repeated operation.
Laser selective sintering technology has the advantage of being able to process a variety of materials, including metals, ceramics, coated sand and so on. In the process of laser sintering, there is no need to set up support structure. The final product has good precision and high strength. Compared with the previous several technologies, it has obvious advantages and is widely used.
Application of 3D printing ceramic materials technology
The traditional process to prepare alumina ceramics is cumbersome and time-consuming. Compared with the traditional process, 3D printing ceramics have the advantages of a shorter production cycle, lower cost, convenient processing and strong operability. Therefore, using 3D printing technology to prepare alumina ceramics will become a new revolutionary development, further expanding the sales market of alumina ceramics, and will be widely used in construction, aerospace and electronic consumer goods.
The researchers first used the spray granulation technology to prepare alumina powder with a particle size controlled at 10-150 m, and then printed alumina ceramic with good mechanical properties by laser selective sintering technology.
2, tricalcium phosphate ceramics
The chemical composition of tricalcium phosphate is very similar to that of bone. It has the advantages of non-variability and good biocompatibility, and is widely used in the medical field. At present, 3D printing technology of tricalcium phosphate ceramics has been systematically studied abroad. The main technological process is to prepare high-quality tricalcium phosphate ceramics by mixing 100g tricalcium phosphate powder with ethanol and milling for 6h. The slurry is dried twice and then the green body is formed by inkjet deposition and printing technology.
3, porous silicon nitride ceramics
In the field of 3D printing porous silicon nitride ceramics, experts used high-purity silicon powder with particle size of 7.2 micron as raw material and dextrin as binder to prepare silicon nitride powder with particle size of less than 200 micron by granulation process. Porous silicon nitride ceramics were synthesized by 3D printing and step-heating sintering under nitrogen protection with purity greater than 99.999%.