Elaboration of Printable Nanopowder Zirconia Suspensions for Vat Photopolymerization
Source abstract
Abstract
This study focuses on preparing and optimizing a submicron zirconia (ZrO₂) suspension for vat photopolymerization (SLA) 3D printing. The suspension includes TZ-3YS-E zirconia powder, acrylate-based monomers (HDDA and TMPTA), a dispersant (Disperbyk-103), and a photoinitiator (TPO). It was prepared using a ball-milling process to ensure homogeneity and optimal dispersion. Rheological properties were assessed to determine the ideal dispersant concentration and milling time, aiming for a low-viscosity and stable suspension. Sedimentation tests were performed to evaluate suspension stability, identifying optimal parameters at 5 wt% dispersant concentration and 120 minutes of ball milling. Additionally, an original curing depth experimental tool was built to optimize printing parameters such as laser speed and power, revealing a maximum over-polymerization of 30% in the lower layer. Finally, the ZrO₂ suspensions with optimal parameters were used to print complex-shaped objects.
Source: openaire · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Photopolymerization techniques and applications · Additive Manufacturing and 3D Printing Technologies · Advanced Polymer Synthesis and Characterization
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (34)
Show source-provided references
1. Y. Lakhdar, C. Tuck, J. Binner, A. Terry, and R. Goodridge, Additive Manufacturing of Advanced Ceramic Materials, Prog. Mater. Sci., 2021, 116, 100736.10.1016/j.pmatsci.2020.100736 ↗
2. A. Velasco-Hogan, J. Xu, and M.A. Meyers, Additive Manufacturing as a Method to Design and Optimize Bioinspired Structures, Adv. Mater., 2018, 30(52), p 1800940.10.1002/adma.201800940 ↗
3. Q. Zhang, X. Yang, P. Li, G. Huang, S. Feng, C. Shen, B. Han, X. Zhang, F. Jin, F. Xu, and T.J. Lu, Bioinspired Engineering of Honeycomb Structure – Using Nature to Inspire Human Innovation, Prog. Mater. Sci., 2015, 74, p 332–400.10.1016/j.pmatsci.2015.05.001 ↗
4. T. Chartier and A. Badev, 2013 Rapid Prototyping of Ceramics, Handbook of Advanced Ceramics, Elsevier, Amsterdam. pp 489–524 https://doi.org/10.1016/B978-0-12-385469-8.00028-9.10.1016/B978-0-12-385469-8.00028-9 ↗
5. Z. Chen, Z. Li, J. Li, C. Liu, C. Lao, Y. Fu, C. Liu, Y. Li, P. Wang, and Y. He, 3D Printing of Ceramics: A Review, J. Eur. Ceram. Soc., 2019, 39(4), p 661–687.10.1016/j.jeurceramsoc.2018.11.013 ↗
6. A. Zocca, P. Colombo, C.M. Gomes, and J. Günster, Additive Manufacturing of Ceramics: Issues, Potentialities, and Opportunities, J. Am. Ceram. Soc., 2015, 98(7), p 1983–2001.10.1111/jace.13700 ↗
7. T. Chartier, V. Pateloup, and C. Chaput, Élaboration de Pièces Céramiques Par Fabrication Additive, Verres et céramiques, 2018 https://doi.org/10.51257/a-v1-n480710.51257/a-v1-n4807 ↗
8. R. Chaudhary, P. Fabbri, E. Leoni, F. Mazzanti, R. Akbari, and C. Antonini, Additive Manufacturing by Digital Light Processing: A Review, Prog Addit Manuf, 2023, 8(2), p 331–351.10.1007/s40964-022-00336-0 ↗
9. M. Ziaee and N.B. Crane, Binder Jetting: A Review of Process, Materials, and Methods, Addit. Manuf., 2019, 28, p 781–801.
10. I.L.D. Camargo, M.M. Morais, C.A. Fortulan, and M.C. Branciforti, A Review on the Rheological Behavior and Formulations of Ceramic Suspensions for Vat Photopolymerization, Ceram. Int., 2021, 47(9), p 11906–11921.10.1016/j.ceramint.2021.01.031 ↗
11. S. Zakeri, M. Vippola, and E. Levänen, A Comprehensive Review of the Photopolymerization of Ceramic Resins Used in Stereolithography, Addit. Manuf., 2020, 35, 101177.
12. C.-J. Bae, A. Ramachandran, K. Chung, and S. Park, Ceramic Stereolithography: Additive Manufacturing for 3D Complex Ceramic Structures, J. Korean Ceram. Soc., 2017, 54(6), p 470–477.10.4191/kcers.2017.54.6.12 ↗
13. S.Y. Song, M.S. Park, D. Lee, J.W. Lee, and J.S. Yun, Optimization and Characterization of High-Viscosity ZrO2 Ceramic Nanocomposite Resins for Supportless Stereolithography, Mater. Des., 2019, 180, 107960.10.1016/j.matdes.2019.107960 ↗
14. G. Ding, R. He, K. Zhang, M. Xia, C. Feng, and D. Fang, Dispersion and Stability of SiC Ceramic Slurry for Stereolithography, Ceram. Int., 2020, 46(4), p 4720–4729.10.1016/j.ceramint.2019.10.203 ↗
15. A. Bagheri and J. Jin, Photopolymerization in 3D Printing, ACS Appl. Polym. Mater., 2019, 1(4), p 593–611.10.1021/acsapm.8b00165 ↗
16. E. Peng, D. Zhang, and J. Ding, Ceramic Robocasting: Recent Achievements, Potential, and Future Developments, Adv. Mater., 2018, 30(47), p 1802404.10.1002/adma.201802404 ↗
17. X. Li, H. Zhong, J. Zhang, Y. Duan, H. Bai, J. Li, and D. Jiang, Dispersion and Properties of Zirconia Suspensions for Stereolithography, Int J Appl. Ceram. Tech, 2020, 17(1), p 239–247.10.1111/ijac.13321 ↗
18. J.B. Hooper, and K.S. Schweizer, Theory of Phase Separation in Polymer Nanocomposites, Macromolecules, 2006, 39(15), p 5133–5142.10.1021/ma060577m ↗
19. K. Zhang, R. He, G. Ding, C. Feng, W. Song, and D. Fang, Digital Light Processing of 3Y-TZP Strengthened ZrO2 Ceramics, Mater. Sci. Eng. A, 2020, 774, 138768.10.1016/j.msea.2019.138768 ↗
20. “Ceramic Powder - Zirconia | https://Www.Tosoheurope.Com,” n.d., https://www.tosoheurope.com/our-products/ceramic-materials. Accessed 29 August 2024.
21. A. Goswami, A.K.N. Balashanmugam, A.M. Umarji, and G. Madras, Optimization of Rheological Properties of Photopolymerizable Alumina Suspensions for Ceramic Microstereolithography, Ceram. Int., 2014, 40(2), p 3655–3665.10.1016/j.ceramint.2013.09.059 ↗
22. K. Zhang, R. He, C. Xie, G. Wang, G. Ding, M. Wang, W. Song, and D. Fang, Photosensitive ZrO2 Suspensions for Stereolithography, Ceram. Int., 2019, 45(9), p 12189–12195.10.1016/j.ceramint.2019.03.123 ↗
23. J. Tarabeux, V. Pateloup, P. Michaud, and T. Chartier, Development of a Numerical Simulation Model for Predicting the Curing of Ceramic Systems in the Stereolithography Process, J. Eur. Ceram. Soc., 2018, 38(11), p 4089–4098.10.1016/j.jeurceramsoc.2018.03.052 ↗
24. R.B.S. Gowda, C.S. Udayagiri, and D.D. Narendra, Studies on the Process Parameters of Rapid Prototyping Technique (Stereolithography) for the Betterment of Part Quality, Int. J. Manuf. Eng., 2014, 2014, p 1–11.
25. V. Sevriugina, D. Pavliňák, F. Ondreáš, O. Jašek, M. Štaffová, and P. Lepcio, Matching Low Viscosity with Enhanced Conductivity in Vat Photopolymerization 3D Printing: Disparity in the Electric and Rheological Percolation Thresholds of Carbon-Based Nanofillers Is Controlled by the Matrix Type and Filler Dispersion, ACS Omega, 2023, 8(48), p 45566–45577.10.1021/acsomega.3c05683 ↗
26. M.N. Cooke, J.P. Fisher, D. Dean, C. Rimnac, and A.G. Mikos, Use of Stereolithography to Manufacture Critical-sized 3D Biodegradable Scaffolds for Bone Ingrowth, J. Biomed. Mater. Res., 2003, 64B(2), p 65–69.10.1002/jbm.b.10485 ↗
27. T. Marie, Z. Du, C.L. Gan, S. Marinel, V.S. Sridharan, and C. Manière, Debinding and Sintering Optimization of Stereolithography Based Silicon Nitride Parts for Attaining Centimetric Wall-Thickness Shapes, J. Eur. Ceram. Soc., 2025, 45(2), 116911.10.1016/j.jeurceramsoc.2024.116911 ↗
28. R. He, W. Liu, Z. Wu, D. An, M. Huang, H. Wu, Q. Jiang, X. Ji, S. Wu, and Z. Xie, Fabrication of Complex-Shaped Zirconia Ceramic Parts via a DLP- Stereolithography-Based 3D Printing Method, Ceram. Int., 2018, 44(3), p 3412–3416.10.1016/j.ceramint.2017.11.135 ↗
29. M.-S. Kim, M.-H. Hong, B.-K. Min, Y.-K. Kim, H.-J. Shin, and T.-Y. Kwon, Microstructure, Flexural Strength, and Fracture Toughness Comparison between CAD/CAM Milled and 3D-Printed Zirconia Ceramics, Appl. Sci., 2022, 12(18), p 9088.10.3390/app12189088 ↗
30. L.-G. Yoo, N.-S. Pang, S.-H. Kim, and B.-Y. Jung, Mechanical Properties of Additively Manufactured Zirconia with Alumina Air Abrasion Surface Treatment, Sci. Rep., 2023, 13(1), p 9153.10.1038/s41598-023-36181-6 ↗
31. Z. Mei, Y. Lu, Y. Lou, P. Yu, M. Sun, X. Tan, J. Zhang, L. Yue, and H. Yu, 2021 Determination of Hardness and Fracture Toughness of Y-TZP Manufactured by Digital Light Processing through the Indentation Technique, BioMed Res. Int. J., 2021, 1, p 6612840.10.1155/2021/6612840 ↗
32. X. Tan, Y. Lu, J. Gao, Z. Wang, C. Xie, and H. Yu, Effect of High-Speed Sintering on the Microstructure, Mechanical Properties and Ageing Resistance of Stereolithographic Additive-Manufactured Zirconia, Ceram. Int., 2022, 48(7), p 9797–9804.10.1016/j.ceramint.2021.12.181 ↗
33. S.-Y. Yang, Y.-H. Koh, and H.-E. Kim, Digital Light Processing of Zirconia Suspensions Containing Photocurable Monomer/Camphor Vehicle for Dental Applications, Materials, 2023, 16(1), p 402.10.3390/ma16010402 ↗
34. W.A. Sarwar, J.-H. Kang, and H.-I. Yoon, Optimized Zirconia 3D Printing Using Digital Light Processing with Continuous Film Supply and Recyclable Slurry System, Materials, 2021, 14(13), p 3446.10.3390/ma14133446 ↗