Robocasting of Bi-Component Ceramic Inks
MELLO RIGON F. 1, WILLENBACHER N. 1
1 Karlsruhe Institute of Technology, Karlsruhe, Germany
Robocasting, or Direct Ink Writing (DIW), is a promising technique for additive manufacturing of ceramics due to its simplicity and relatively low cost when compared to other methods for 3D printing ceramics. To achieve the desired printed structure, the rheological properties of the ceramic suspensions must be carefully controlled, with inks usually displaying high viscosity and yield strength for improved shape retention. This rheological behavior, however, makes it difficult for removing entrapped air from the ink, which might lead to unwanted pores and defects in the final printed construct. In this work, we propose an innovative method to circumvent this problem by using two different ceramic suspensions that are conveyed separately and mixed together in the print head, immediately before extrusion, using a static mixer prior to the nozzle. The rheology of the initial ceramic suspensions, which exhibit lower viscosity and yield strength than the final mixed ink, makes it easier to completely remove air bubbles, leading to a defect-free 3D printed structure. By employing the capillary suspension concept, we are able to tune the flow behavior of the initial ceramic suspensions and improve their stability against sedimentation. This bi-component approach allows us to work with initial components with yield strength bellow 200 Pa for easier conveying and de-airing while the final ceramic ink displays yield point above 3000 Pa after mixing, which enables printing complex structures. We compare the rheological properties of precursor components with the final mixed ink, evaluating how the mixing method influences ink rheology and microstructure of the sintered ceramic.