3D printing - Rapid prototyping components with properties depending on orientation

3D Printing was used as a Rapid Prototyping process, using a ZCorp ZP402 printer, in order to manufacture ceramic components. By means of 3D printing it was possible to produce ceramic models and components starting from CAD constructions and 3D scans of the objects. Many different ceramic raw materials were assessed, with the best results obtained for Al2O3 materials. These were ultimately used in order to analyse the capability of 3D printing in manufacturing ceramic objects. As the binder component could not be introduced via the Canon printing head, it was blended into the ceramic powder in dry form. An aqueous ink was used. As expected, printed components displayed a high porosity, which is consistent with the layer-by-layer construction method and the sticking together of individual particles primarily within the layers. Thus a very low fracture strength resulted. The properties of the components were dependent on their orientation within the printing cavity. The smallest values were obtained in the zdirection of the layer construction (σ0 = 5 MPa), with intermediate values in the x-direction of the printer head movement (σ0 = 10 MPa) and the largest values along y (σ0 = 20 MPa). Areas of technical application of 3D printed ceramic objects, for example, are in filtration and bone substitution, as a result of the porous properties. A main advantage of 3D printing is the production of components, that cannot be made by traditional methods. Further uses as wear-resistant composite materials, following infiltration with aluminium and bronze melts are entirely conceivable.