Optimization of Alumina- and Zirconia-Based Ceramic Printing Using the Fused Filament Fabrication (FFF) Technique

• Grant number: 25/10200-4
• Support Opportunities: Scholarships in Brazil - Scientific Initiation
• Start date: August 01, 2025
• End date: July 31, 2026
• Field of knowledge: Engineering - Materials and Metallurgical Engineering - Nonmetallic Materials
• Principal Investigator: Ana Paula da Luz
• Grantee: Thales Filipe Silveira de Andrade
• Host Institution: Centro de Ciências Exatas e de Tecnologia (CCET). Universidade Federal de São Carlos (UFSCAR). São Carlos , SP, Brazil
• Associated research grant: 24/04483-0 - Additive manufacturing of ceramic parts via FFF technique: optimizing fabrication parameters and debinding procedures, AP.R

Abstract

The growing demand for customization of advanced ceramic components has driven the advancement of additive manufacturing (AM) as an alternative to conventional forming processes. Among the available technologies, fused filament fabrication (FFF) stands out for its ability to produce parts with complex geometries and the potential to achieve high density after sintering. However, 3D printing of ceramics such as alumina (Al¿O¿) and zirconia (ZrO¿) still presents significant challenges, including weak interlayer adhesion, crack formation, and residual porosity, all of which can compromise the final performance of the parts. This project aims to investigate the influence of printing parameters-such as speed, infill pattern, and infill percentage-on the physical, microstructural, and mechanical properties of specimens produced with commercial alumina and zirconia filaments. The experimental stages include physicochemical characterization of the filaments, sample printing, chemical and thermal debinding, sintering at 1600¿°C, and subsequent analysis of both green and sintered bodies. Properties such as density, porosity, water absorption, flexural strength, and linear shrinkage will be evaluated, alongside microstructural analysis via optical and electron microscopy. The goal is to identify optimized printing conditions that yield parts with improved structural integrity, low porosity, and satisfactory mechanical performance. The results are expected to contribute to the development of FFF as a viable route for the production of dense, functional ceramics and to strengthen the national scientific foundation in the field of ceramic 3D printing.