Additive manufacturing of ceramic parts via FFF technique: optimizing fabrication parameters and debinding procedures

• Grant number: 24/04483-0
• Support Opportunities: Regular Research Grants
• Start date: November 01, 2024
• End date: October 31, 2026
• Field of knowledge: Engineering - Materials and Metallurgical Engineering - Nonmetallic Materials
• Principal Investigator: Ana Paula da Luz
• Grantee: Ana Paula da Luz
• Host Institution: Centro de Ciências Exatas e de Tecnologia (CCET). Universidade Federal de São Carlos (UFSCAR). São Carlos , SP, Brazil
• Associated researchers: Carlos Alberto Fortulan ; Italo Leite de Camargo ; Márcio Raymundo Morelli ; Murilo Daniel de Mello Innocentini ; Paolo Colombo ; Rodrigo Bresciani Canto ; Vinicius Fiocco Sciuti

Abstract

Additive manufacturing (AM) techniques have gained significant attention in recent years due to their ability to produce high-precision ceramic parts with complex geometries, meeting the demands of various industrial applications. However, challenges persist in achieving parts with precise printing and defect-free characteristics. These challenges stem from intrinsic properties and processing conditions of ceramic materials, such as high melting points and the need for thermal treatments for consolidation. Post-processing stages, including debinding and sintering of AM-fabricated parts, may result in residual porosity, crack formation, and reduced mechanical strength. In this context, this project aims to evaluate the printing parameters and debinding procedures of alumina and zirconia ceramic parts produced via the fused filament fabrication (FFF) technique. The primary objective is to investigate the influence of various parameters (such as sample geometry, solvent temperature, heating rate, and environment atmosphere) on the solvent and thermal debinding kinetics of the printed parts. The goal is to define optimum conditions for processing samples with complex geometries, based on experimental measurements and mathematical models. Comprehensive characterization of the manufactured ceramic parts will be conducted using conventional techniques (TG/DSC, FTIR) alongside innovative methods enabling in-situ data collection. To validate the calculation results, the most suitable debinding conditions will be applied to the preparation of a rotor inspired by a centrifugal blood pump for mechanical circulatory support. (AU)

Scientific publications

(References retrieved automatically from Web of Science and SciELO through information on FAPESP grants and their corresponding numbers as mentioned in the publications by the authors)

ALVES, P. L. A.; CAMARGO, I. L.; VERZA, J. R.; LUZ, A. P.. Impact of debinding atmosphere and sintering additives on the fabrication of alumina ceramics via vat photopolymerization. CERAMICS INTERNATIONAL, v. 51, n. 7, p. 10-pg., 2025-02-28. (23/08728-5, 24/04483-0)