Session: 16-01-01: Government Agency Student Poster Competition

Paper Number: 150456

150456 - Enhanced De-Binding Process of Dlp 3d-Printed Ceramics Components 

Among the various additive manufacturing (AM) techniques, vat photopolymerization (VP)-based methods, particularly stereolithography (SL) and digital light processing (DLP), have emerged as leading methods in ceramic fabrication. These processes excel in producing parts with exceptional feature resolution, surface finish, and forming efficiency. Indeed, complex shaping by subtractive technology is difficult and wasteful when dealing with ceramics, owing to their intrinsic hardness and brittleness. The VP process, which utilizes a photocurable ceramic slurry composed of reactive monomers, photoinitiators, and other additives, enables the layer-by-layer construction of intricate structures through UV light exposure. This approach encompasses four key stages: preparation of the ceramic suspension, photopolymerization to form green bodies, de-binding, and high-temperature sintering. The preparation of the ceramic suspension is crucial, as it directly impacts the quality of the final product. Factors such as particle size distribution, solid loading, and rheological properties must be carefully optimized to ensure proper dispersion and stability of the ceramic particles within the photopolymerizable resin. Despite these advancements, the de-binding phase remains a critical bottleneck, often demanding a prolonged preconditioning period of several days depending on the binding mass ratio. This time-intensive step, crucial for successful sintering, requires meticulous control to prevent defects such as deformation, layer delamination, and cracks induced by pressure gradients from evolving gases. The removal of organic binders must be carefully managed to maintain the structural integrity of the green body while allowing for the escape of decomposition products. Recent research efforts have explored various strategies to accelerate the de-binding process, including combinations of solvent and thermal methods, aiming to reduce processing time and minimize defects. Some innovative approaches involve the use of supercritical fluids, which can penetrate the green body and extract binders without causing significant delamination to the ceramic structure. Other researchers are investigating the potential of microwave-assisted de-binding, which offers the promise of more uniform heating and faster processing times. Improving this key step is not just about working faster. It could completely change the game for industries like dentistry, aerospace, electronics, and medicine. Our research contributes to this vital area by introducing an innovative de-binding method for parts printed by DLP technology. This approach significantly reduces processing time while maintaining structural integrity, representing a potential breakthrough in ceramic additive manufacturing. The ongoing refinement of these processes stands to bridge the gap between the rapid shaping capabilities of AM technologies and the traditionally time-consuming post-processing steps, paving the way for broader adoption of ceramic AM across multiple industries and applications.

Presenting Author: Mahdi Mosadegh The University of Texas at Dallas

Presenting Author Biography: Mahdi Mosadegh is a Mechanical Engineering PhD student at The University of Texas at Dallas. He joined UTD in Fall 2022 and is working under the supervision of Dr. Majid Minary. His research focuses on ceramics produced by vat photopolymerization, with particular emphasis on improving debinding processes. His current work involves vat polymerization, debinding, and sintering techniques. He has experience working with DSC/TGA, DLP printers, Rheology test device, and Nano Indentation equipment. Mahdi's research interests include advanced ceramic manufacturing processes, optimization of post-processing techniques for additively manufactured ceramics, and applications of these technologies in green energy solutions.

Authors:

Mahdi Mosadegh The University of Texas at Dallas
Moein Khakzad The University of Texas at Dallas
Zahra Sepasi The University of Texas at Dallas
Majid Minary-Jolandan The University of Texas at Dallas