Glass-supported Large Scale Additive Manufacturing of Sustainable Ceramics
ELSAYED H. 1,2, GOBBIN F. 1, BERNARDO E. 1, COLOMBO P. 1,3
1 University of Padova, Industrial Engineering Department, Padova, Italy; 2 Refractories, Ceramics and Building Materials Department, National Research Centre, Cairo, Egypt; 3 Department of Materials Science and Engineering, Pennsylvania State University, University Park, Pennsylvania, United States
The flexibility in shaping ceramic components with potential use in architecture/constructions, offered by additive manufacturing, will be intrinsically coupled with sustainability, according to the use of inorganic waste, with special attention to glass wastes from different industries. Along with the additive manufacturing of glass-based mixtures with large and complex geometries, alkali activation represents an opportunity for a much broader range of applications. In the current research, we will use a novel and unique powder bed-based (3DP) additive manufacturing equipment, produced by an Italian company (Desamanera Srl, Rovigo, Italy), that utilizes a printing head containing a large number of nozzles (196), enabling the printing of a layer in a few seconds (the building envelope is 60x60x60 cm3). The nozzles spray a liquid that selectively hardens the particles in the powder bed. In particular, our work will focus on : 1) disclosing the potential of powder beds based on the glass as the main component for the development of geopolymers as well as stable zeolite-like gels, binding unreacted particles; 2) selecting suitable, low-cost and/or waste inorganic powders, which generate a powder bed of desired quality and contribute to the final component as ‘inert’ phases or as a further reactive component, when in contact with the printing liquid. A full characterization of morphology, microstructure, mechanical and (selected) functional properties of the produced components, will be presented.