Search Results (35)

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

How would it be possible to functionalize ceramic aggregates for use in refractories? In this work, we demonstrate how paste extrusion can be used to fabricate layered and porous Nb-Al₂O₃-based composite refractories for adjusting thermal and electrical conductivity. Additive manufacturing is used to generate a specific sequence of alumina and composite layers. After drying, the samples were sintered at 1600 °C, crushed, and sieved into particle sizes up to 3150 µm. The rheology of the paste revealed the intended shear-thinning behavior with microcrack formation between the yield and flow strain. The sintered material showed promising thermal-shock characteristics reaching plateau values after the third cycle without signs of further structural damage up to the fifth thermal shock. The layered microstructure was retained after crushing the composites, establishing functionalization of the refractory granules for all particle sizes. 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

Current treatment methods for critical bone defects involve the implantation of large bone grafts, which are limited by tissue availability and failure to heal correctly with high complication rates. Bioengineered scaffolds have emerged, which deploy biodegradable, highly osteoconductive materials in porous structures to accommodate the high mass transport requirements of large bone defects. Ideal scaffold biomaterials require a balance between strength, composition, and osteoconduction, a balance which has yet to be discovered. Naturally derived materials like deproteinized bovine bone mineral (DBBM) have seen successful clinical use for decades as bone void fillers, but their granular or putty form lacks the interconnected porosity required to treat large defects. Leveraging the clinical success of DBBM, this paper presents the first fabrication of highly porous scaffolds composed of naturally derived, deproteinized bone mineral, for potential use in large bone defects. Ovine bone mineral powder was prepared from fresh ovine bone, fabricated into a photopolymeric slurry and 3D-printed using a photocasting process into 67% porous gyroid scaffolds. Ovine bone mineral composition, surface microstructure, compressive properties, and failure probability were evaluated and compared to gyroid scaffolds composed of tricalcium phosphate. Both scaffold types were similar, with characteristics in the low range of human cancellous bone. Full article

This study investigates the application of robocasting technology for fabricating high-density yttria-stabilized zirconia (8YSZ) electrolytes used in solid oxide fuel cells (SOFCs). The primary goal is to overcome the limitations of traditional manufacturing techniques, such as low density and poor microstructural control. Using a combination of hydrothermal synthesis, rheological testing, and robocasting, we achieved dense 8YSZ structures (over 95% density) with minimal porosity. The fabricated electrolytes underwent sintering and debinding processes, with thermal treatment profiles optimized for structural integrity. A microstructural analysis through SEM and XRD confirmed the formation of stable crystalline phase. This research opens new avenues for the use of additive manufacturing in electrochemical applications, particularly for producing complex ceramic components with superior characteristics. Full article

This article presents a procedure for selecting optimal ceramic paste formulations dedicated to the 3D printing process using robocasting technology. This study investigated pastes with varying ceramic powder particle sizes and different proportions of additives, such as ceramic microspheres and nutshells. This selection process allowed for the classification of ceramic mixtures into those suitable and unsuitable for this additive manufacturing technique. Subsequently, the viscosity of the pastes was measured, and extrudability tests were performed to determine the force required for extrusion and evaluate the quality of the extruded material. In the final stage, the setting time of the ceramic pastes was assessed to establish the drying time of the printed elements. It was found that the length of the extruded band of ceramic paste was inversely proportional to the Al₂O₃ content. Moreover, the extrusion force for samples with varying ceramic powder particle sizes (MG1–MG5) ranged from 133 to 166 N, compared to 77 N for the base sample (BM1). The obtained results enable further development in robocasting additive technology, including the development of a rapid and effective method for validating ceramic pastes used in this process. Full article

The formation of defects, due to drying, in robocasted ceramic objects is an important issue arising from non-uniform shrinkage of the material during this step in the process. Common methods for shrinkage measurement are not well suited to the small size of robocasted cords or the complexity of robocasted objects. Innovative methods for shrinkage measurement were developed using non-destructive optical vision techniques with computer-controlled data acquisition, allowing measurement on millimetric cords and on specific zones of a product. The study of a single porcelain cord revealed an anisometric shrinkage related to the orientation of grains during extrusion. A differential shrinkage at the macroscopic scale was also measured on a robocasted object, indicating a moisture content gradient in the material. The methods presented in this paper are of particular relevance to real-time control of the drying process for robocasted objects. Full article

In order to investigate the most extreme conditions in which materials potentially applicable in reusable thermal shields can be operated, ultra-high-temperature ZrB₂ ceramics with 20 vol.% MoSi₂ were prepared using two different techniques, cold isostatic pressing (CIP) and robocasting (RC, an additive manufacturing technique), followed by consolidation using pressureless spark plasma sintering (SPS). The oxidation behavior of the resulting materials was analyzed in low-pressure dissociated air at three different temperatures, namely 1800, 2000 and 2200 K. Using XRD and surface and cross-section SEM (coupled with EDS), zirconia was found to form at all three temperatures, while silica was only present at 1800 K, with gaseous SiO forming at a higher temperature. The elaboration technique influences the density of the ceramic, and less dense materials undergo deeper oxidation. This investigation suggests that 2000 K is already beyond the maximum temperature threshold at which damage to ceramics is limited by the formation of protective silica. This study confirms that the selected material is a promising candidate for thermal protection applications. Full article

The restoration of ancient ceramics has attracted widespread attention as it can reveal the overall appearance of ancient ceramics as well as the original information and artistic charm of cultural relics. However, traditional manual restoration is constrained due to its time-consuming nature and susceptibility to damaging ancient ceramics. Herein, a three-dimensional (3D) printing technique was employed to accurately restore Chinese Yuan Dynasty Longquan celadon using hollow Al₂O₃ microsphere-modified 3D printing paste. The results show that the hollow Al₂O₃ microsphere content plays a vital role in the printability, physical properties, and firing performance of the modified 3D printing paste. The printed green bodies show no noticeable spacing or voids under moderate rheological conditions. The as-prepared ceramic body modified with 6 wt.% hollow Al₂O₃ microspheres and fired at 1280 °C exhibits optimal bending strength of 56.66 MPa and a relatively low density of 2.16 g∙cm⁻³, as well as a relatively uniform longitudinal elastic modulus and hardness along the interlayer. This 3D printing technique based on hollow Al₂O₃ microsphere-modified paste presents a promising pathway for achieving non-contact and damage-free restoration of cultural relics. Full article

In this work, a 3D printing methodology based on the robocasting of catalytic ink pastes was applied to obtain structured matrix-like cylinders as innovative materials for an effective utilization of carbon dioxide. The influence of three different binders (i.e., PEI, HPMC and MC) on the physio-chemical, mechanical and catalytic properties of multi-channel monoliths was studied against a reference binder-free powdered system in order to envisage the effectiveness of the printing procedure in realizing hybrid advanced materials at a higher control and reproducibility than from traditional preparation techniques. In terms of textural and structural properties, the micro-extruded 3D cylinders only evidenced a slight difference in terms of relative crystallinity, with minor effects on the surface area exposure in relation to the specific binder used during the direct ink writing process. More importantly, the typology of binder significantly affected the rheological properties of the catalytic ink, with the need of a controlled viscosity to ensure a suitable thixotropic behaviour of the extrudable pastes, finally determining an optimal mechanical resistance of the final 3D monolith. The experimental validation of the hybrid multi-channel cylinders under conditions of CO₂ hydrogenation demonstrated the great potential of additive manufacturing in the realization of catalyst architectures characterized by unique features and fidelity scarcely reproducible via conventional synthetic techniques. Full article

Triply Periodic Minimal Surfaces (TPMS) are promising structures for bone tissue engineering scaffolds due to their relatively high mechanical energy absorption, smoothly interconnected porous structure, scalable unit cell topology, and relatively high surface area per volume. Calcium phosphate-based materials, such as hydroxyapatite and tricalcium phosphate, are very popular scaffold biomaterials due to their biocompatibility, bioactivity, compositional similarities to bone mineral, non-immunogenicity, and tunable biodegradation. Their brittle nature can be partially mitigated by 3D printing them in TPMS topologies such as gyroids, which are widely studied for bone regeneration, as evidenced by their presence in popular 3D-printing slicers, modeling systems, and topology optimization tools. Although structural and flow simulations have predicted promising properties of other TPMS scaffolds, such as Fischer–Koch S (FKS), to the best of our knowledge, no one has explored these possibilities for bone regeneration in the laboratory. One reason for this is that fabrication of the FKS scaffolds, such as by 3D printing, is challenged by a lack of algorithms to model and slice this topology for use by low-cost biomaterial printers. This paper presents an open-source software algorithm that we developed to create 3D-printable FKS and gyroid scaffold cubes, with a framework that can accept any continuous differentiable implicit function. We also report on our successful 3D printing of hydroxyapatite FKS scaffolds using a low-cost method that combines robocasting with layer-wise photopolymerization. Dimensional accuracy, internal microstructure, and porosity characteristics are also presented, demonstrating promising potential for the 3D printing of TPMS ceramic scaffolds for bone regeneration. Full article

Zirconia-based materials are widely used in dentistry due to their biocompatibility and suitable mechanical and tribological behavior. Although commonly processed by subtractive manufacturing (SM), alternative techniques are being explored to reduce material waste, energy consumption and production time. 3D printing has received increasing interest for this purpose. This systematic review intends to gather information on the state of the art of additive manufacturing (AM) of zirconia-based materials for dental applications. As far as the authors know, this is the first time that a comparative analysis of these materials’ properties has been performed. It was performed following the PRISMA guidelines and using PubMed, Scopus and Web of Science databases to select studies that met the defined criteria without restrictions on publication year. Stereolithography (SLA) and digital light processing (DLP) were the techniques most focused on in the literature and the ones that led to most promising outcomes. However, other techniques, such as robocasting (RC) and material jetting (MJ), have also led to good results. In all cases, the main concerns are centered on dimensional accuracy, resolution, and insufficient mechanical strength of the pieces. Despite the struggles inherent to the different 3D printing techniques, the commitment to adapt materials, procedures and workflows to these digital technologies is remarkable. Overall, the research on this topic can be seen as a disruptive technological progress with a wide range of application possibilities. Full article

This work was devoted to the first multi-parametric unitary comparative analysis of a selection of sintered piezoceramic materials synthesised by solid-state reactions, aiming to delineate the most promising biocompatible piezoelectric material, to be further implemented into macro-porous ceramic scaffolds fabricated by 3D printing technologies. The piezoceramics under scrutiny were: KNbO₃, LiNbO₃, LiTaO₃, BaTiO₃, Zr-doped BaTiO₃, and the (Ba_0.85Ca_0.15)(Ti_0.9Zr_0.1)O₃ solid solution (BCTZ). The XRD analysis revealed the high crystallinity of all sintered ceramics, while the best densification was achieved for the BaTiO₃-based materials via conventional sintering. Conjunctively, BCTZ yielded the best combination of functional properties—piezoelectric response (in terms of longitudinal piezoelectric constant and planar electromechanical coupling factor) and mechanical and in vitro osteoblast cell compatibility. The selected piezoceramic was further used as a base material for the robocasting fabrication of 3D macro-porous scaffolds (porosity of ~50%), which yielded a promising compressive strength of ~20 MPa (higher than that of trabecular bone), excellent cell colonization capability, and noteworthy cytocompatibility in osteoblast cell cultures, analogous to the biological control. Thereby, good prospects for the possible development of a new generation of synthetic bone graft substitutes endowed with the piezoelectric effect as a stimulus for the enhancement of osteogenic capacity were settled. Full article

The design and synthesis of sol-gel silica-based hybrid materials and composites offer significant benefits to obtain innovative biomaterials with controlled porosity at the nanostructure level for applications in bone tissue engineering. In this work, the combination of robocasting with sol-gel ink of suitable viscosity prepared by mixing tetraethoxysilane (TEOS), gelatin and β-tricalcium phosphate (β-TCP) allowed for the manufacture of 3D scaffolds consisting of a 3D square mesh of interpenetrating rods, with macropore size of 354.0 ± 17.0 μm, without the use of chemical additives at room temperature. The silica/gelatin/β-TCP system underwent irreversible gelation, and the resulting gels were also used to fabricate different 3D structures by means of an alternative scaffolding method, involving high-resolution laser micromachining by laser ablation. By this way, 3D scaffolds made of 2 mm thick rectangular prisms presenting a parallel macropore system drilled through the whole thickness and consisting of laser micromachined holes of 350.8 ± 16.6-micrometer diameter, whose centers were spaced 1312.0 ± 23.0 μm, were created. Both sol-gel based 3D scaffold configurations combined compressive strength in the range of 2–3 MPa and the biocompatibility of the hybrid material. In addition, the observed Si, Ca and P biodegradation provided a suitable microenvironment with significant focal adhesion development, maturation and also enhanced in vitro cell growth. In conclusion, this work successfully confirmed the feasibility of both strategies for the fabrication of new sol-gel-based hybrid scaffolds with osteoconductive properties. Full article

In this study, the mechanical properties of two classes of robocast glass scaffolds are obtained through Computed micro-Tomography (micro-CT) based Finite Element Modeling (FEM) with the specific purpose to explicitly account for the geometrical defects introduced during manufacturing. Both classes demonstrate a fiber distribution along two perpendicular directions on parallel layers with a ${90}^{\circ }$ tilting between two adjacent layers. The crack pattern identified upon compression loading is consistent with that found in experimental studies available in literature. The finite element models have demonstrated that the effect of imperfections on elastic and strength properties may be substantial, depending on the specific type of defect identified in the scaffolds. In particular, micro-porosity, fiber length interruption and fiber detaching were found as key factors. The micro-pores act as stress concentrators promoting fracture initiation and propagation, while fiber detachment reduces the scaffold properties substantially along the direction perpendicular to the fiber plane. Full article