Search Results (68)

Inspired by the Bouligand helicoidal architecture of the dactyl club of the peacock mantis shrimp, this study employed direct ink writing (DIW) 3D printing to construct a three-level synergistic toughening system composed of nano-SiO₂, microscale flake alumina, and a macroscale helicoidal structure. The effects of nano-SiO₂ content, Bouligand helix angle, and flake alumina content on the flexural strength and fracture toughness of the composite ceramics were systematically investigated. The results showed that the optimal nano-SiO₂ addition was 7 wt%, yielding a fracture toughness of 1.03 MPa·m^1/2, which was 13% higher than that of pure alumina. The introduced intergranular glassy phase transformed the rigid grain-boundary bonding into a moderately strong gradient interface, resulting in higher fracture toughness for all SiO₂-containing samples than for pure alumina. The Bouligand structure further increased the fracture toughness to a maximum of 1.45 MPa·m^1/2 at a helix angle of 10°, representing a 39% improvement over the 0° sample. When microscale flake alumina was incorporated into the optimal matrix containing 7 wt% SiO₂, the best overall mechanical performance was achieved at a flake alumina content of 5 wt%, where the flakes directly dissipated fracture energy through pull-out, fracture, and bridging mechanisms. The synergistic effect of the three structural levels was most pronounced at a helix angle of 20°, at which the sample containing 5 wt% flake alumina achieved a fracture toughness of 2.07 MPa·m^1/2 with almost no loss in flexural strength, corresponding to a 113% improvement over the sample without flake alumina. These results demonstrate that three-level synergy can be achieved through nanoscale interfacial optimization, microscale energy dissipation by reinforcing phases, and macroscale crack deflection induced by the helicoidal structure, thereby providing important theoretical and experimental support for the multiscale design of high-performance bioinspired ceramic materials. Full article

Inspired by the erosion-resistant dorsal armor of the desert scorpion, this study developed biomimetic ZTA ceramic composites with enhanced resistance to solid particle erosion. Three biomimetic configurations, namely convex-bump (CH-O), convex-curved-surface (CH-CS), and convex hybrid rigid–flexible (CH-HS) structures, were fabricated by direct ink writing (DIW) 3D printing. Their erosion performance was evaluated by gas–solid two-phase erosion tests at impact angles ranging from 15° to 90°, and the underlying mechanisms were elucidated through erosion morphology analysis, actual impact angle analysis, and stress-wave propagation analysis. The results showed that the erosion rate of all samples first increased and then decreased with increasing impact angle, reaching a maximum at around 60°. Compared with the smooth control sample, CH-O exhibited lower erosion resistance under low-angle erosion conditions but showed clear improvement under high-angle erosion conditions, with the erosion resistance increased by 18.39–32.54%. CH-CS further improved the erosion resistance of CH-O, with enhancements of 14.31–53.92% at low impact angles and 24.57–35.17% at high impact angles. Among all the biomimetic designs, CH-HS exhibited the best overall erosion resistance, showing an additional improvement of 9.22–32.16% over CH-CS across the tested impact angle range. The superior erosion resistance was attributed to the synergistic effects of convex-bump morphology, curved-surface-induced particle deflection, and rigid–flexible coupling. These biomimetic features modified the actual impact angle of the particles, deflected their trajectories, reduced direct particle impact, and generated a shadow effect, while the flexible layer dissipated impact energy through reflection unloading at the rigid–flexible interface. This study provides a novel strategy for the biomimetic design of erosion-resistant ceramic composites and offers new insights into mitigating erosion damage in ceramic-based mechanical components. Full article

Silica-based bioceramics are promising bone substitutes with tunable degradation and mechanical properties. We aimed to assess bone response in critical-size calvarial defects in rats, empty or filled with 3D-printed sphene ceramic (CaTiSiO₅) scaffolds produced using direct ink writing from preceramic polymers and reactive fillers. Scaffold characterization was performed using scanning electron microscopy, X-ray diffraction, porosity analysis, and compressive strength testing. Bilateral cylindrical 5 mm calvarial defects were created in 20 rats: one was randomly filled with sphene scaffold, while the contralateral remained empty. Ten animals were killed at 4 weeks, the rest at 8 weeks. Specimens were collected for micro-X-ray computed tomography (micro-CT) analysis, followed by undecalcified histology. The scaffolds exhibited porous structure with complete sphene phase purity and compressive strength of 17.91 MPa (SD 4.6). In vivo, no adverse event was noted during healing. Overall bone regeneration—as measured by BV/TV—was comparable between groups: Bone volume/total volume (BV/TV) increased over time in the empty and sphene groups, reaching ~40%, with no significant differences between groups or time points. BV/TV was significantly higher in the external regions of the defects compared to the internal areas in both groups at the two time points. The sphene group showed a significantly greater volume of new bone extending beyond the original cortical boundary at both 4 and 8 weeks (p = 0.013). In the sphene group histology revealed partial bone ingrowth within the scaffold, while bone in the control group was limited to defect edges. After 8 weeks, new bone adjacent to the cortical surface was thicker in the sphene group (p < 0.05). These initial findings are consistent with prior preclinical studies, supporting the biocompatibility and osteoconductive nature of sphene ceramic scaffolds. Full article

In additive manufacturing technologies, the use of pastes and inks based on materials such as clay to create three-dimensional objects layer by layer has opened new possibilities in fields such as engineering and biomedicine. This review article aims to provide a comprehensive understanding of 3D printing of ceramic pastes through Direct Ink Writing (DIW), also referred to as Robocasting. DIW offers specific advantages for ceramic 3D printing, including the ability to extrude highly loaded pastes with customized rheological properties to accommodate a broad spectrum of ceramic compositions, varying from conventional clays to advanced ceramics. It is characterized by filament deposition control, which facilitates the fabrication of complex, porous, or customized architectures while simultaneously minimizing material waste. Through a bibliometric analysis of the literature published between 2020 and 2024, the most relevant studies regarding printing system architectures, ceramic paste formulations, and adjustment of parameters to obtain high-quality parts were identified. This work presents relevant and accurate explanations of the DIW technology, supporting researchers and industry professionals seeking to initiate or improve ceramic 3D printing processes for a wide range of applications. Full article

Advanced ceramics are known for their lightweight, high-temperature resistance, corrosion resistance, and biocompatibility. They are crucial in energy conversion, environmental protection, and aerospace fields. This review highlights the recent advancements in ceramic matrix composites, high-entropy ceramics, and polymer-derived ceramics, alongside various fabrication techniques such as three-dimensional printing, advanced sintering, and electric-field-assisted joining. Beyond the fabrication process, we emphasize how different processing methods impact microstructure, transport properties, and performance metrics relevant to catalysis. Additive manufacturing routes, such as direct ink writing, digital light processing, and binder jetting, are discussed and normalized based on factors such as relative density, grain size, pore architecture, and shrinkage. Cold and flash sintering methods are also examined, focusing on grain-boundary chemistry, dopant compatibility, and scalability for catalyst supports. Additionally, polymer-derived ceramics (SiOC, SiCN, SiBCN) are reviewed in terms of their catalytic performance in hydrogen evolution reaction, oxygen evolution reaction, oxygen reduction reaction, and CO₂ reduction reaction. CeO₂-ZrO₂ composites are particularly highlighted for their use in environmental catalysis and high-temperature gas sensing. Furthermore, insights on the future industrialization, cross-disciplinary integration, and performance improvements in catalytic applications are provided. Full article

Additive manufacturing methods can constitute a valuable alternative to conventional production techniques for components used in the heavy industry, particularly in foundry applications. This innovative manufacturing approach enables an expanded product portfolio as well as higher precision and geometrical complexity of ceramic components. One additive technology applicable to ceramic processing is robocasting, classified within the direct ink writing (DIW) family. In this method, a semi-fluid ceramic paste is extruded to build the part layer by layer; the shaped green body is subsequently fired (sintered) to attain its final functional properties. This study presents the results of materials characterization of printed ceramic filters, encompassing phase composition analysis, density measurements, three-point bending strength testing, hardness, and microstructural examination. The investigations demonstrated that the oxide ceramic Al₂O₃ processed by the modern robocasting method exhibits mechanical performance at a comparably high level relative to classical manufacturing routes (slip casting, ceramic injection molding, dry pressing). Moreover, the porosity results indicate that 3D printing technology enables lower post-sintering porosity. Full article

The increasing demand for novel tissue engineering (TE) applications in bone tissue regeneration underscores the importance of exploring advanced manufacturing techniques and biomaterials for personalised treatment approaches. Three-dimensional printing (3DP) technology facilitates the development of implantable devices with intricate geometries, enabling patient-specific therapeutic solutions. Although Fused Filament Fabrication (FFF) and Direct Ink Writing (DIW) are widely utilised for fabricating bone-like implants, the need for multiple processing steps often prolongs the overall production time. In this study, a single-step melt-extrusion 3DP technique was performed to develop multi-material scaffolds including bioceramics, hydroxyapatite (HA), and β-tricalcium phosphate (TCP) in both their bioactive and calcined forms at 10% and 20% w/w, within polycaprolactone (PCL) matrices. Printing parameters were optimised, and physicochemical properties of all biomaterials and final forms were evaluated. Thermal degradation and surface morphology analyses assessed the consistency and distribution of the ceramics across the different formulations. The tensile testing of the scaffolds defined the impact of each ceramic type and wt% on scaffold flexibility performance, while in vitro cell studies determined the cytocompatibility efficiency. Hence, all 3D-printed PCL–ceramic composite scaffolds achieved structural integrity and physicochemical and thermal stability. The mechanical profile of extruded samples was relevant to the ceramic consistency, providing valuable insights for further mechanotransduction investigations. Notably, all materials showed high cell viability and proliferation, indicating strong biocompatibility. Therefore, this additive manufacturing (AM) process is a precise and fast approach for developing biomaterial-based scaffolds, with potential applications in surgical restoration and support of segmental bone defects. Full article

Settlement on the Moon will require full exploitation of its resources if such settlements are to be permanent. Such in situ resource utilisation (ISRU) has primarily been focused on accessing water ice at the lunar poles and the use of raw lunar regolith as a compressive building material. Some work has also examined the extraction of metals, but there has been little consideration of the many useful ceramics that can be extracted from the Moon and how they may be fabricated. We introduce a strategy for full lunar industrialisation based on a circular lunar industrial ecology and examine the contribution of ceramics. We review ceramic fabrication methods but focus primarily on 3D printing approaches. The popular direct ink writing method is less suitable for the Moon and other methods require polymers which are scarce on the Moon. This turns out to be crucial, suggesting that full industrialisation of the Moon cannot be completed until the problem of ceramic fabrication is resolved, most likely in conjunction with polymer synthesis from potential carbon sources. Full article

Developing advanced nuclear fuel technologies is critical for high-performance applications such as nuclear thermal propulsion (NTP). This study explores the feasibility of direct ink writing (DIW) for fabricating ceramic pellets for potential nuclear applications. Zirconium carbide (ZrC) is used as a matrix material and vanadium carbide (VC) is used as a surrogate for uranium carbide (UC) in this study. A series of ink formulations were developed with varying concentrations of VC and nanocrystalline cellulose (NCC) to optimize the rheological properties for DIW processing. Post-sintering analysis revealed that conventionally sintered samples at 1750 °C exhibited high porosity (>60%), significantly reducing the compressive strength compared to dense ZrC ceramics. However, increasing VC content improved densification and mechanical properties, albeit at the cost of increased shrinkage and ink flow challenges. Spark plasma sintering (SPS) achieved near-theoretical density (~97%) but introduced geometric distortions and microcracking. Despite these challenges, this study demonstrates that DIW offers a viable route for fabricating ZrC-based ceramic structures, provided that sintering strategies and ink rheology are further optimized. These findings establish a baseline for DIW of ZrC-based materials and offer valuable insights into the porosity control, mechanical stability, and processing limitations of DIW for future nuclear fuel applications. Full article

Solid-state electrolytes (SSEs) have emerged as a promising solution for next-generation lithium-ion batteries due to their excellent safety and high energy density. However, their practical application is still hindered by critical challenges such as their low ionic conductivity and high interfacial resistance at room temperature. The innovative application of 3D printing in the field of electrochemistry, particularly in solid-state electrolytes, endows energy storage devices with attractive characteristics. In this study, ceramic-in-gel polymer electrolytes (GPEs) based on PVDF-HFP/PAN@LLZTO were fabricated using a direct ink writing (DIW) 3D printing technique. Under the optimal printing conditions (printing speed of 40 mm/s and fill density of 70%), the printed electrolyte exhibited a uniform and dense sponge-like porous structure, achieving a high ionic conductivity of 5.77 × 10⁻⁴ S·cm⁻¹, which effectively facilitated lithium-ion transport. A structural analysis indicated that the LLZTO fillers were uniformly dispersed within the polymer matrix, significantly enhancing the electrochemical stability of the electrolyte. When applied in a LiFePO₄|GPEs|Li cell configuration, the electrolyte delivered excellent electrochemical performance, with high initial discharge capacities of 168 mAh·g⁻¹ at 0.1 C and 166 mAh·g⁻¹ at 0.2 C, and retained 92.8% of its capacity after 100 cycles at 0.2 C. This work demonstrates the great potential of 3D printing technology in fabricating high-performance GPEs. It provides a novel strategy for the structural design and industrial scalability of lithium-ion batteries. Full article

Drop-on-demand (DoD) printing is an additive manufacturing technique that utilizes functional inks containing nanoparticles (NPs) to fabricate electronic circuits or devices on a variety of substrates. One of the most promising applications for such technology is the aerospace industry, due to the capability of this method to fabricate custom low-weight geometric films. This work evaluates the performance of a gold (Au) nanoparticle (NP)-based film printed on a ceramic substrate for avionics applications, following the environmental temperature guidance of the Radio Technical Commission for Aeronautics (RTCA) DO-160. Experimental results show that the Au films, printed on alumina substrates, successfully survived the environmental temperature procedures for airborne equipment. The thermal coefficient of resistance (TCR) of the films was measured to be $2.7\times {10}^{-3} {°\mathrm{C}}^{-1}.$ Full article

Inspired by the Bouligand structure of the mantis shrimp’s dactyl club, in this study, we employed direct ink writing 3D printing technology to fabricate bioinspired gradient ceramic samples with varying gradient spacings and rotation angles. A rigid–flexible coupled bioinspired gradient ceramic–epoxy resin composite was successfully constructed based on epoxy resin infiltration. The effects of gradient variations and rotation angles on mechanical properties were systematically investigated with flexural strength and fracture toughness tests. The experimental results revealed that, at a fixed rotation angle, both the flexural strength and fracture toughness initially increased and then decreased with an increase in gradient spacing. The infiltration of epoxy resin significantly enhanced the mechanical performance of the composite samples. Specifically, the maximum flexural strength of 63.35 MPa was achieved at Δd = 0.08 and a rotation angle of 12°, while the highest fracture toughness of 2 MPa/m² was observed at Δd = 0.1 and a rotation angle of 12°. A failure analysis indicated that the introduction of gradient structures and epoxy resin infiltration altered the failure forms of traditional ceramics, with the primary toughening mechanisms including crack deflection, fiber pull-out, and crack branching. In this study, we successfully developed a rigid–flexible coupled bioinspired gradient ceramic–epoxy resin composite with excellent mechanical properties based on bioinspired design and gradient optimization, providing new insights and methodologies for the design and fabrication of high-performance ceramic materials. Full article

Our research outlines a method for creating chemosensors utilizing hybrid nanostructures derived from TiO₂ ceramic nanotubes alongside conducting polymers, with embedded gold nanoparticles. The method used to create hybrid nanostructures from ceramic nanotubes and conducting polymers was drop-casting. AFM analysis highlighted an increased roughness, particularly for PANI-EB, exhibiting a significantly larger grain size exceeding 3.5 μm, with an increased inclusion of gold and uniform arrangement on the surface. The Rku parameter values being around three suggested that the layers primarily exhibited peaks rather than depressions, showing a Gaussian distribution. A chemiresistor was created by using an ink-jet printer and a multilayer metallization was achieved with commercial silver ink for printed electronics. Based on the experimental calibration curve, which exhibits adequate linearity over a wider range of H₂S concentrations in air up to 1 ppm, the detection limit was established at 0.1 ppm, a threshold appropriate for recognizing oral diseases. The sensor is a simple, affordable, and durable device designed for individual use, offering significant benefits for patients by enabling improved tracking of the syndrome’s advancement or treatment success. Full article

Inspired by the ventral scale structure of the oriental sand boa, this study successfully fabricated multiscale bioinspired alumina (Al₂O₃) ceramics by combining the excellent mechanical properties, high-temperature resistance, and high hardness of ceramic composites with direct ink writing (DIW) 3D printing technology and femtosecond laser processing. A MoS₂ thin film was then deposited on the ceramic surface via radio frequency magnetron sputtering (PVD) to systematically investigate the impact of bioinspired structures on the tribological properties of ceramic composites under both dry and lubricated conditions. Experimental results demonstrated that bioinspired structures at different scales exhibited significant friction-reducing and wear-resistant characteristics compared to blank structures. Specifically, under room-temperature conditions, the friction coefficients of bioinspired ceramic composites with solid lubricants and oil lubrication were 0.3 and 0.148, respectively, indicating excellent tribological performance. These findings confirm the synergistic lubrication effect between bioinspired structures, two-dimensional solid lubricants, and lubricating oil, which significantly enhanced the friction-reducing and wear-resistant properties of ceramic components. Therefore, the synergistic design of multiscale bioinspired structures and solid lubricants provides an innovative strategy for the advanced application of ceramic components. Full article

In-situ porous mullite ceramics with varying pore size and porosity were fabricated using 3D printing. The pore size was controlled by adjusting the size of polymethyl methacrylate (PMMA) microspheres. The effect of sintering temperature on phase evolution was also examined. Additionally, the impact of PMMA microsphere size and content on the rheological properties of the printing inks was investigated. The results indicated that alumina and microsilica fully transformed into mullite at 1550 °C. The influence of PMMA microsphere content and size on the porosity, mechanical properties, and thermal conductivity of 3D-printed porous mullite ceramics was also studied. The 3D-printed porous mullite ceramic prepared with 15 μm PMMA microspheres exhibited a porosity of 44.38%, a flexural strength of 58.53 MPa, and a thermal conductivity of 2.21 W/(m·K). This printing strategy offers a simple and effective method for fabricating porous mullite ceramics. Full article