Digital light processing of advanced ceramics: current investigations and perspectives at Politecnico di Torino
COPPOLA B. 1, FIUME E. 1, BERTERO A. 1, INSERRA B. 1, MONTANARO L. 1, TULLIANI J. 1, PALMERO P. 1
1 INSTM R.U. Lince Laboratory, Department of Applied Science and Technology (DISAT), Politecnico di Torino. , TORINO, Italy
Additive manufacturing technologies, and specifically vat-photopolymerization techniques (namely, Stereolithography, SL, and Digital Light Processing, DLP), have demonstrated a superior ability compared to traditional technologies in fabricating ceramics with customized and unprecedented shapes, controlled architectures and inner features, and good surface finishing.
Recent advances of the LINCE-DISAT research group of Politecnico of Torino in shaping advanced ceramics by DLP are here briefly reported, showing how the appealing possibility to realize complex finished objects is widening their applicability to different research fields, from medicine to environmental applications.
Structural ceramics based on ceria-stabilized zirconia are fabricated by DLP, through a study that methodically addresses open issues related to slurry elaboration and printability, where additional challenges are due to the significant absorbance of ceria in the UV range, responsible for reducing photopolymerization efficiency.
Calcium phosphate ceramics are fabricated as bulk materials, shaped as bars suitable for mechanical characterization, to fill the gap on the reliability of 3D printing technologies for these bioceramics. Specifically, the role of hydroxyapatite median particle size (MPS), curing depth-to-layer thickness ratio (CD/LT), and debinding process on the printing/debinding flaws and flexural strength of the sintered parts is investigated. The study demonstrated that a minimum MPS value, established at 0.9 mm, was required to fabricate specimens with appreciable flexural strength. Further, a progressive decrease of CD/LT induced a progressive disappearance of the above printing and debinding flaws, and enhancement of the mechanical strength.
Textured alumina/zirconia ceramics composites, in which alumina platelets are embedded in a fine zirconia matrix, are fabricated by DLP. In fact, in our equipment, the movement of the slurry under a doctor blade generates a shear field, able to align the anisotropic particles dispersed in the slurry. In the study, the composition (in terms of alumina platelets/zirconia ratio) and microstructures are correlated with physical/mechanical properties of the printed and sintered samples.
Finally, a new system for CO2 capture, based on a mullite substrate fabricated by DLP and properly functionalized with Metal Organic Frameworks (MOFs), is developed. Mullite complex architectures, including honeycomb and Schwartz primitive triply periodic minimal surface (TPMS), have been designed and printed. HKUST-1 (Cu3(BTC)2), one of the most widely studied MOF, was selected due to their CO2 absorption potential, and growth on the surface of the mullite sintered substrates. Samples tested in a catalytic bench reactor showed an efficient CO2 adsorption capacity, especially for the TPMS structure due to its higher surface area.
The aim of this work, within the above reported studies, is to show the state-of-the-art of the research group in the development of advanced ceramics for DLP, and to open the research to new and intriguing collaborations.