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Research progress in ceramic slurries and rheology via photopolymerization-based 3D printing |
Wenli LI1, Hongzhi ZHOU2, Weiwei LIU1, Haining YU1, Jing WANG1, Lei GONG1, Zhanwen XING1,*( ) |
1 School of Mechanical and Electric Engineering, Soochow University, Suzhou 215131, Jiangsu, China 2 College of Mechanical Engineering, Hunan Institute of Science and Technology, Yueyang 414006, Hunan, China |
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Abstract Ceramic 3D printing based on stereolithography has attracted wide attention because it can fabricate complex ceramic components with high dimensional accuracy, good surface finish, uniform microstructure, and excellent mechanical properties. It is one of the important technical means to achieve high-performance parts by additive manufacturing. The core of the technology is to prepare ceramic slurries with high solid loading and good printability, and its composition has a vital influence on the curing effect and printing process. In this review, two main additive manufacturing methods, stereolithography (SL) and digital light processing (DLP), commonly used in ceramic 3D printing were introduced, and advantages and disadvantages of the two methods were compared. Based on the research work in the field of ceramic slurries in recent years, the effects of monomer/oligomer and diluent, dispersant, physical properties of ceramic particles and solid loading on viscosity, shear thinning/thickening behavior, viscoelasticity, yield stress were discussed. Finally, the main development trends and challenges of ceramic slurries via stereolithography were put forward in, and a general guiding principle for the construction of ceramic slurries with high solid loading was provided.
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Received: 31 August 2021
Published: 18 July 2022
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Corresponding Authors:
Zhanwen XING
E-mail: xingzhanwen@suda.edu.cn
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Principle of photopolymerization 3D printing technologies (a)stereolithography (SL); (b)digital light processing (DLP)
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Main composition of photopolymerized ceramic slurries
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Monomer | Functionality | Viscosity/(mPa·s) | Refractive index | Reference | 2-HEA | 1 | 10 | 1.445 | [42-43] | HEMA | 1 | 11 | 1.453 | [17] | ACMO | 1 | 12-15 | 1.512 | [12, 44] | IBOA | 1 | 2-9 | 1.476 | [45-46] | HDDA | 2 | 5-10 | 1.455 | [10, 31-33] | DEGDA | 2 | 12 | 1.463 | [47] | PEG400DA | 2 | 26 | 1.465 | [32, 44, 48] | TPGDA | 2 | 10-15 | 1.450 | [9, 49] | NPGPO2DA | 2 | 17 | 1.446 | [45] | TMPTA | 3 | 80-140 | 1.474 | [10, 35, 50] | DPHA | 5/6 | 4000-7000 | 1.488 | [37] |
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Photocurable monomers commonly used for ceramic slurries
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Diluent | Viscosity/(mPa·s) | Refractive index | Reference | Phenoxyethanol (POE) | | 1.539 | [17] | Glycerol (glycerin) | 950 | 1.474 | [51-52] | Polyethylene glycol (PEG) | 60-100 | 1.465 | [18] | Decahydronaphthalene (decalin) | 2-3 | 1.474 | [46] | Butoxyethyl acetate (BEA) | 2 | 1.413 | [37] | Butyl phthalate (DBP) | 6-7 | 1.490 | [6] | Camphor | Solid | | [53] |
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Diluents commonly used for ceramic slurries
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Name | Chemical description | Reference | Oleic acid | Unsaturated carboxylic acid (18 carbons) | [31, 54-55] | KH560 | Silane coupling 3-glycidoxypropylthrimethoxysilane | [12, 44] | Anti-Terra-U100 | Salt of unsaturated polyamine amides and low-molecular acidic polyesters | [5] | BYK-W 969 | A solution of a hydroxy-functional alkylammonium salt of an acidic copolymer | [56] | Disper BYK-111 | Copolymer with an acid group | [35, 57-58] | Solsperse 41000 | 100% active polymeric dispersant compatible with UV-curable systems | [13, 15] | Variquac CC 42 NS | Polypropoxy quaternary ammonium chloride | [44, 59-60] |
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Dispersants commonly used in formulations of ceramic slurries
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Ceramic | Particle size/μm | Solid loading/% | Viscosity/(mPa·s) | Reference | Alumina | 0.4 | 45 | 1620 | [34] | Alumina | 0.4 | 40 | 2020 | [42] | Alumina | 0.6 | 44.2 | 25000(30 s-1) | [12] | Zirconia | 0.09 | 45 | 2300 | [13] | Zirconia | 0.385 | 40 | 2900 | [59] | Alumina+zirconia | 0.4+0.2 | 40 | 380 | [48] | Alumina+zirconia | 0.430+0.143 | 50 | 32000(30 s-1) | [5] | Silica | 2.29 | 50 | 110 | [8] | Calcium phosphate | 1.57 | 48 | 160 | [53] | Hydroxyapatite | 3.97 | 40 | 3700(10 s-1) | [24] | Zirconia | 13+0.02(70∶30) | 50 | 6200(30 s-1) | [35] | Alumina | 1.66 | 58 | | [40] |
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Particle size, solid loading and viscosity in typical formulations of ceramic slurries
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Ceramic slurries viscosity curves for different solid loadings[38]
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Illustration of conformal contactless support[5]
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