Multi-material ceramic material extrusion 3D printing with granulated injection molding feedstocks

Ceramics have a wide range of industrial applications due to their unique properties, which include high hardness, resistance to wear and corrosion, high melting points, and excellent electrical and thermal insulation. Ceramics are used in the aerospace industry for applications such as turbine blades, engine components, and heat shields due to their high-temperature resistance, durability, and light weight. They are also used in the electronics industry for applications such as capacitors, resistors, and insulators due to their excellent electrical properties, high dielectric strength, and thermal stability. Moreover, ceramics are commonly used in the medical industry for applications such as dental implants, joint replacements, and bone grafts due to their biocompatibility, strength, and resistance to wear and corrosion. Ceramics are used in the energy industry for applications such as fuel cells, thermal barrier coatings, and electrical insulators due to their high-temperature resistance, chemical stability, and low thermal conductivity. These are just a few examples of the many industrial applications of ceramics. Due to their unique properties, ceramics are a versatile material that can be used in a wide range of industries and applications.

3D printing has revolutionized many industries, and ceramics is no exception. The technology has allowed for the creation of complex shapes and intricate designs that were previously impossible to achieve with traditional ceramic production methods. 3D printing allows for a greater degree of design flexibility, which means that ceramic objects can be designed and produced with intricate shapes and details. This technology allows for the creation of complex geometries and organic shapes that are difficult to produce using traditional methods. Moreover, 3D printing technology can save time in the production process. It eliminates the need for molds and allows for rapid prototyping, which is particularly useful for designers and artists who need to produce multiple iterations of their designs before finalizing the product. Furthermore, it allows for precise control over the amount of material used, which means less waste in the production process. This is particularly important for ceramics, as it is a material that can be challenging to recycle. With 3D printing, ceramic objects can be customized to fit specific needs or requirements. This makes it possible to produce one-of-a-kind objects or small-batch productions, which can be particularly useful for artists or designers looking to create unique pieces.

Material extrusion, also known as fused filament fabrication (FFF), is one of the most popular methods used for 3D printing ceramics. The process involves the extrusion of a thermoplastic material, such as a polymer, loaded with ceramic particles. The thermoplastic acts as a binder, holding the ceramic particles together during the printing process. After printing, the object is fired in a kiln to burn off the binder and sinter the ceramic particles together.  Material extrusion is one of the most affordable 3D printing methods available, making it accessible to a wide range of users.

Indeed, the technology is relatively easy to use and does not require highly skilled operators and can be used with a variety of ceramic materials, including porcelain, stoneware, and earthenware. While 3D printing has created new possibilities for the fabrication of ceramic components, problems including high production costs, the need for specialized equipment, and the need for customized feedstocks have hindered its general acceptance. In a new study published in the peer-reviewed journal Ceramics International, Dr. René Wick-Joliat, Dr. Martina Schroffenegger, and Prof. Dirk Penner from the IMPE – Institute of Materials and Process Engineering in Switzerland developed a new revolutionary multi-material ceramic material extrusion 3D printing approach that makes use of granulated injection molding feedstocks. Intricate and complicated ceramic components may now be made with accuracy and efficiency, which has the potential to revolutionize the ceramic industry. The authors created a novel 3D printing method to fabricate multi-material ceramic components from granulated injection molding feedstocks to overcome these difficulties. The ability to print many ceramic materials at once, each with their own unique characteristics, opens the door for the creation of cutting-edge methods for producing high-performance functional components. The research team’s inventiveness may be seen in their capacity to reuse the feedstocks utilized in the standard granulated injection molding procedure. The cost of 3D printing can potentially be reduced because of the usage of these feedstocks, making it more widely available. Also, the extrusion method has been modified by the researchers to assure homogeneous material deposition, producing precise components with greater quality requirements.

The authors optimized different manufacturing steps which may impact the end product. The multi-material ceramic extrusion process was improved by examining the crucial factors of material flow behavior, nozzle shape, and printing speed. This new method may find use in the fields of aircraft, electronics, and healthcare. The ability to produce intricately formed, lightweight ceramic parts with great temperature resistance might have a substantial impact on the design of future spacecraft and airplanes. Multi-material ceramic 3D printing has the potential to have a substantial influence on the electronics industry by making it easier to produce complex, high-performance devices with enhanced thermal management and electrical insulation. The biomedical industry will benefit from the development of ceramic implants and prostheses that can be altered to meet the unique requirements of each patient in terms of both clinical results and quality of life.

The potential of 3D printing in ceramics is vast. Material extrusion is a popular method for 3D printing ceramics due to its low cost and ease of use. As the technology continues to advance, it is likely that we will see even more complex designs and shapes being produced, as well as larger and more robust objects. Additionally, 3D printing has the potential to reduce the environmental impact of ceramic production by reducing waste and optimizing material usage. The new method by Dr. René Wick-Joliat and colleagues addresses current 3D printing limitations and expand the capabilities of ceramic 3D printing.