Pneumatic dispensing of aqueous Al₂O₃ suspensions via material extrusion additive manufacturing
Material extrusion, also known as Robocasting or Direct Ink Writing (DIW) is an efficient and eco-friendly additive manufacturing method for fabricating large and thick ceramic components, such as alumina. While screw-based extrusion is the prevalent approach due to its precise control over printing...
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| Language: | English |
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Elsevier
2025-07-01
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| Series: | Next Materials |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2949822825002680 |
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| author | Flavie Lebas Sylvain Marinel Christelle Bilot Romuald Herbinet Loïc Le Pluart Charles Manière |
| author_facet | Flavie Lebas Sylvain Marinel Christelle Bilot Romuald Herbinet Loïc Le Pluart Charles Manière |
| author_sort | Flavie Lebas |
| collection | DOAJ |
| description | Material extrusion, also known as Robocasting or Direct Ink Writing (DIW) is an efficient and eco-friendly additive manufacturing method for fabricating large and thick ceramic components, such as alumina. While screw-based extrusion is the prevalent approach due to its precise control over printing parameters, pneumatic-based extrusion is gaining attention for its suitability in automated processes and reduced handling requirements. However, pneumatic extrusion faces challenges, primarily the narrower range of printable rheological behavior. Achieving a balance between extrudability and the self-supporting capacity of printed structures is critical. Moreover, bubble elimination, easily addressed in screw-based extrusion, remains a significant challenge in pneumatic systems. To overcome these issues, optimal concentrations of dispersants, ceramic loading, and additives were determined to achieve the desired shear-thinning rheological properties suitable for pneumatic extrusion. Additionally, this study, by employing a rapid one-step ball milling method for suspension preparation, is somewhat unique, providing a streamlined alternative to traditional processes. A degassing study was conducted to minimize bubble formation, ensuring print quality. Using the optimized parameters, including extrusion pressure and layer height, complex structures were successfully printed. After sintering at 1450 °C, the samples exhibited a 99.5 % dense microstructure with an average grain size of 1.71 µm. The alumina demonstrated excellent mechanical properties, achieving a hardness of 2094 HV at 1450°C, which is well aligned with the literature. |
| format | Article |
| id | doaj-art-368cf0d582a74ebda827818f65ca8a62 |
| institution | OA Journals |
| issn | 2949-8228 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Next Materials |
| spelling | doaj-art-368cf0d582a74ebda827818f65ca8a622025-08-20T02:01:28ZengElsevierNext Materials2949-82282025-07-01810075010.1016/j.nxmate.2025.100750Pneumatic dispensing of aqueous Al₂O₃ suspensions via material extrusion additive manufacturingFlavie Lebas0Sylvain Marinel1Christelle Bilot2Romuald Herbinet3Loïc Le Pluart4Charles Manière5Université Caen Normandie, ENSICAEN, CNRS, Normandie Univ, CRISMAT UMR6508, Caen F-14000, France; Corresponding authors.Université Caen Normandie, ENSICAEN, CNRS, Normandie Univ, CRISMAT UMR6508, Caen F-14000, FranceUniversité Caen Normandie, ENSICAEN, CNRS, Normandie Univ, CRISMAT UMR6508, Caen F-14000, FranceUniversité Caen Normandie, ENSICAEN, CNRS, Normandie Univ, LCMT UMR6507, Caen F-14000, FranceUniversité Caen Normandie, ENSICAEN, CNRS, Normandie Univ, LCMT UMR6507, Caen F-14000, FranceUniversité Caen Normandie, ENSICAEN, CNRS, Normandie Univ, CRISMAT UMR6508, Caen F-14000, France; Corresponding authors.Material extrusion, also known as Robocasting or Direct Ink Writing (DIW) is an efficient and eco-friendly additive manufacturing method for fabricating large and thick ceramic components, such as alumina. While screw-based extrusion is the prevalent approach due to its precise control over printing parameters, pneumatic-based extrusion is gaining attention for its suitability in automated processes and reduced handling requirements. However, pneumatic extrusion faces challenges, primarily the narrower range of printable rheological behavior. Achieving a balance between extrudability and the self-supporting capacity of printed structures is critical. Moreover, bubble elimination, easily addressed in screw-based extrusion, remains a significant challenge in pneumatic systems. To overcome these issues, optimal concentrations of dispersants, ceramic loading, and additives were determined to achieve the desired shear-thinning rheological properties suitable for pneumatic extrusion. Additionally, this study, by employing a rapid one-step ball milling method for suspension preparation, is somewhat unique, providing a streamlined alternative to traditional processes. A degassing study was conducted to minimize bubble formation, ensuring print quality. Using the optimized parameters, including extrusion pressure and layer height, complex structures were successfully printed. After sintering at 1450 °C, the samples exhibited a 99.5 % dense microstructure with an average grain size of 1.71 µm. The alumina demonstrated excellent mechanical properties, achieving a hardness of 2094 HV at 1450°C, which is well aligned with the literature.http://www.sciencedirect.com/science/article/pii/S2949822825002680Al2O3 ceramicAdditive manufacturingMaterial extrusionRheologyBubble eliminationBall milling |
| spellingShingle | Flavie Lebas Sylvain Marinel Christelle Bilot Romuald Herbinet Loïc Le Pluart Charles Manière Pneumatic dispensing of aqueous Al₂O₃ suspensions via material extrusion additive manufacturing Next Materials Al2O3 ceramic Additive manufacturing Material extrusion Rheology Bubble elimination Ball milling |
| title | Pneumatic dispensing of aqueous Al₂O₃ suspensions via material extrusion additive manufacturing |
| title_full | Pneumatic dispensing of aqueous Al₂O₃ suspensions via material extrusion additive manufacturing |
| title_fullStr | Pneumatic dispensing of aqueous Al₂O₃ suspensions via material extrusion additive manufacturing |
| title_full_unstemmed | Pneumatic dispensing of aqueous Al₂O₃ suspensions via material extrusion additive manufacturing |
| title_short | Pneumatic dispensing of aqueous Al₂O₃ suspensions via material extrusion additive manufacturing |
| title_sort | pneumatic dispensing of aqueous al₂o₃ suspensions via material extrusion additive manufacturing |
| topic | Al2O3 ceramic Additive manufacturing Material extrusion Rheology Bubble elimination Ball milling |
| url | http://www.sciencedirect.com/science/article/pii/S2949822825002680 |
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