The binder jetting (BJ) process shows significant superiority in manufacturing ceramic parts with a complex structure. The performance of the green part is highly reliant on the features of raw materials. A kind of grading zirconia powder M0 was designed, its intrinsic characteristics including microstructure, size and size distribution, bulk density, porosity, hall velocity and spread performance were systematically evaluated. The design principles of M0 were illustrated in detail. Meanwhile, a kind of organic epoxy binder was prepared and its properties including density, viscosity and surface tension were estimated. The jet ability of binder was evaluated quantitatively. The compatibility and bonding strength between binder and powder were assessed through contact angle, infiltration time and microstructure of M0. As a result, M0 and epoxy binder can be successfully applied in the printer, the zirconia structure with good dimensional accuracy (shrinkage rate ≤ ±2%) and flexible strength (1.74 ± 0.28 MPa) were achieved.
HassaninH, EssaK, ElshaerA, Micro-fabrication of ceramics: additive manufacturing and conventional technologies. J Adv Ceram. 2021;10(1):1–27.
2.
WenJ, XieZ, CaoW, Effects of different backbone binders on the characteristics of zirconia parts using wax-based binder system via ceramic injection molding. J Adv Ceram. 2016;5(4):321–328.
3.
ChenZ, SunX, ShangY, Dense ceramics with complex shape fabricated by 3D printing: a review. J Adv Ceram. 2021;10(2):195–218.
4.
HalloranJW.Freeform fabrication of ceramics. Br Ceram Trans. 1999;98(6):299–303.
5.
WangW, QianC, HuM, Optimisation of scanning parameters in stereolithography for dental zirconia ceramic fabrication. Adv Appl Ceram. 2020;119(5/6):244–251.
6.
KhanlarLN, Salazar RiosA, TahmasebA, Additive manufacturing of zirconia ceramic and its application in clinical dentistry: a review. Dent J. 2021;9(9):104.
7.
MostafaeiA, ElliottAM, BarnesJE, Binder jet 3D printing—process parameters, materials, properties, modeling, and challenges. Prog Mater Sci. 2021;119:100707.
8.
ZiaeeM, CraneNB.Binder jetting: a review of process, materials, and methods. Addit Manuf. 2019;28:781–801.
9.
ZhangX, WuX, ShiJ.Additive manufacturing of zirconia ceramics: a state-of-the-art review. J Mater Res Technol. 2020;9(4):9029–9048.
10.
HanY, ZongP-A, HuangM, In-situ synthesis of gadolinium niobate quasi-binary composites with balanced mechanical and thermal properties for thermal barrier coatings. J Adv Ceram. 2022;11(9):1445–1456.
HuangS, YeC, ZhaoH, Binder jetting yttria stabilised zirconia ceramic with inorganic colloid as a binder. Adv Appl Ceram. 2019;118(8):458–465.
13.
HuangS-J, YeC-S, ZhaoH-P, Parameters optimization of binder jetting process using modified silicate as a binder. Mater Manuf Processes. 2020;35(2):214–220.
14.
HöhneP. Utilization of an ultra sound atomizer for spray granulation of oxide ceramic fine powder; 2017.
15.
MirzajanyR, AlizadehM, SaremiM, Suspension preparation of alumina whiskers for spray granulation. Mater Lett. 2018;228:344–347.
16.
JalloLJ, SchoenitzM, DreizinEL, The effect of surface modification of aluminum powder on its flowability, combustion and reactivity. Powder Technol. 2010;204(1):63–70.
17.
DoT, KwonP, ShinCS.Process development toward full-density stainless steel parts with binder jetting printing. Int J Mach Tools Manuf. 2017;121:50–60.
18.
ChenQ, JusteE, LasgorceixM, Binder jetting process with ceramic powders: influence of powder properties and printing parameters. Open Ceram. 2022;9:100218.
19.
MoghadasiM, DuW, LiM, Ceramic binder jetting additive manufacturing: effects of particle size on feedstock powder and final part properties. Ceram Int. 2020;46(10):16966–16972.
20.
GermanRM.Prediction of sintered density for bimodal powder mixtures. Metall Trans A. 1992;23(5):1455–1465.
21.
DuW, RenX, MaC, Ceramic binder jetting additive manufacturing: particle coating for increasing powder sinterability and part strength. Mater Lett. 2019;234:327–330.
22.
MirzababaeiS, PasebaniS.A review on binder jet additive manufacturing of 316L stainless steel. J Manuf Mater Process. 2019;3(3):82.
23.
SuwanprateebJ, SanngamR, PanyathanmapornT.Influence of raw powder preparation routes on properties of hydroxyapatite fabricated by 3D printing technique. Mater Sci Eng C. 2010;30(4):610–617.
24.
MostafaeiA, De VecchisPR, NettleshipI, Effect of powder size distribution on densification and microstructural evolution of binder-jet 3D-printed alloy 625. Mater Des. 2019;162:375–383.
25.
GermanR.Sintering densification for powder mixtures of varying distribution widths. Acta Metall Mater. 1992;40(9):2085–2089.
26.
LvX, YeF, ChengL, Binder jetting of ceramics: powders, binders, printing parameters, equipment, and post-treatment. Ceram Int. 2019;45(10):12609–12624.
27.
BruceCA.Dependence of Ink Jet dynamics on fluid characteristics. IBM J Res Dev. 1976;20(3):258–270.
28.
TehraniBK, MariottiC, CookBS, Development, characterization, and processing of thin and thick inkjet-printed dielectric films. Org Electron. 2016;29:135–141.
29.
DerbyB.Inkjet printing of functional and structural materials: fluid property requirements, feature stability, and resolution. Annu Rev Mater Res. 2010;40:395–414.
30.
JangD, KimD, MoonJ.Influence of fluid physical properties on ink-jet printability. Langmuir. 2009;25(5):2629–2635.
31.
LuthraR, KaurP.An insight into current concepts and techniques in resin bonding to high strength ceramics. Aust Dent J. 2016;61(2):163–173.
32.
MansoAP, SilvaNR, BonfanteEA, Cements and adhesives for all-ceramic restorations. Dent Clin. 2011;55(2):311–332.
33.
ParteliEJ, PöschelT.Particle-based simulation of powder application in additive manufacturing. Powder Technol. 2016;288:96–102.
