Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D...
Transcript of Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D...
![Page 1: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/1.jpg)
Centre for Fine Print Research: 3D Laboratory
Materials and Process Innovation for 3D Printing of Ceramics
David Huson Research Fellow
Centre for Fine Print Research
University of the West of England
![Page 2: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/2.jpg)
Areas of investigation
• The use of 3D printing technologies and CNC machining to translate a computer 3D model into a mould capable of producing a bespoke ceramic artefact
• The use of laser scanning, reverse engineering and digital fabrication techniques to facilitate the production of short runs of bespoke ceramic artefact
• To research the possibilities, and then develop the methodology of forming a bespoke ceramic artefact directly by the use of 3D printing and other RP technologies
![Page 3: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/3.jpg)
3D lab equipment
![Page 4: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/4.jpg)
3D laser scanning
![Page 5: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/5.jpg)
Build Drive Feed Drive
Print Head
Z-‐Corp Powder-‐Binder 3D Prin8ng System
Roller
Build Piston Feed Piston
![Page 6: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/6.jpg)
Z Corp 310 Printer
![Page 7: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/7.jpg)
3D printed artworks
![Page 8: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/8.jpg)
3D printing of ceramic artworks
• The 3D computer model is drawn in a CAD program or generated from data collected by a 3D scanner (or a combination of the two)
• The proprietary material in a Z Corp 3D printer is replaced with a ceramic body powder
• 3D printing of ceramics allows an artist to move directly from the 3D model to a finished article without using traditional modelling and mould making processes
![Page 9: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/9.jpg)
3D printed ceramic test pieces
![Page 10: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/10.jpg)
CAD model of ‘impossible’ ceramic object
![Page 11: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/11.jpg)
Printing object in ceramic powder
![Page 12: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/12.jpg)
Post-processing printed ceramic
![Page 13: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/13.jpg)
3D printed ceramics
![Page 14: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/14.jpg)
Spray dried ceramic body
• Advantage
– Easily available – Prepared body – Correct thermal
expansion
• Disadvantage
– Coarse grain size – Poor green strength – Needs pre-sintering to
post process
![Page 15: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/15.jpg)
3D ceramic printing with ball clay
![Page 16: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/16.jpg)
3D ceramic printing with ball clay
• Problems – Layers curling during
printing – Layers moving
during printing – Cracking and
distortion
![Page 17: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/17.jpg)
3D ceramic printing with ball clay
• Advantage – Easily available – Fine particle size – Better green strength
so no pre-sintering required
• Disadvantage – High plasticity – Low thermal
expansion – Difficult to fit glaze
![Page 18: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/18.jpg)
Earthenware type ceramic body
• Dry blended from powder constituents – ball clay – china clay – silica filler – flux
• Binder additives to improve green strength • Adjust orientation in build bed to reduce layer shift
![Page 19: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/19.jpg)
Printed examples
![Page 20: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/20.jpg)
Fired examples
![Page 21: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/21.jpg)
Earthenware type ceramic body
• Far better but still some problems – Layer shift – Variable surface quality – High porosity – High fired contraction
![Page 22: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/22.jpg)
Layer shift
![Page 23: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/23.jpg)
Dead swallows
![Page 24: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/24.jpg)
Dead swallows
![Page 25: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/25.jpg)
Dead swallows
![Page 26: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/26.jpg)
Dead swallows
![Page 27: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/27.jpg)
![Page 28: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/28.jpg)
To improve the process
• Investigate particle size distribution • Increase green strength of body • Reduce binder saturation • Reduce porosity and contraction • Have ability to use wider range of ceramic bodies
• Decided to develop a process to adapt commercially available ceramic bodies for use with the Z Corp 3D printers
![Page 29: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/29.jpg)
New body characteristics
• Ball milling of body to improve particle size distribution
• Improved binder in body mix to increase green strength
• Reduced binder saturation to eliminate layer shifting
• Adjust the body mix to reduce fired contraction
![Page 30: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/30.jpg)
Firing contraction and porosity
![Page 31: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/31.jpg)
Manta
![Page 32: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/32.jpg)
3D printed in bone china
![Page 33: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/33.jpg)
Removing from bed
![Page 34: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/34.jpg)
Fired with setter
![Page 35: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/35.jpg)
With coloured 3d prints
![Page 36: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/36.jpg)
Trumpet sphere cad model
![Page 37: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/37.jpg)
Urchin cad model
![Page 38: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/38.jpg)
Trumpet sphere 3D printed
![Page 39: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/39.jpg)
Urchin 3D printed
![Page 40: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/40.jpg)
3D printed ceramic
![Page 41: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/41.jpg)
Further developments
• Need to reduce the porosity and fired shrinkage • Need to improve the green strength • Need to improve printing performance and eliminate
layer shift • To achieve these aims it was decided to develop a
new type of ceramic body and process methodology that would work specifically with the characteristics of the Z Corp 3D printing system
![Page 42: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/42.jpg)
![Page 43: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/43.jpg)
![Page 44: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/44.jpg)
![Page 45: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/45.jpg)
![Page 46: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/46.jpg)
![Page 47: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/47.jpg)
![Page 48: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/48.jpg)
![Page 49: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/49.jpg)
![Page 50: Materials and Process Innovation for 3D Printing of …...Centre for Fine Print Research: 3D Laboratory Materials and Process Innovation for 3D Printing of Ceramics David Huson! Research](https://reader033.fdocuments.in/reader033/viewer/2022041815/5e5a9a4fa49cf0739e0e2a81/html5/thumbnails/50.jpg)
Future Developments
• Exhibition of 3D printed ceramic artworks
• Patent application
• License agreement with Z Corp.