Additive manufacturing of binder-coated zirconia on a freeform surface

Advanced ceramics have become indispensable materials for use in diverse industrial sectors due to their exceptional properties, including high mechanical strength, corrosion resistance, oxidation resistance, low thermal conductivity, and remarkable hardness and wear resistance. However, their intrinsic characteristics of high hardness and wear resistance have posed a formidable challenge to their more widespread utilization that is mainly driven by elevated production costs and difficulty in machining complex structures. This study explores the application of additive manufacturing (AM) technologies, specifically material extrusion, for the fabrication of freeform ceramics structures, with a particular focus on binder-coated zirconia. The concept of conformal AM-in which a structure is printed directly onto the surface of a freeform substrate by aligning the topography of the two surfaces-is also explored. Conformal AM overcomes the challenges faced by traditional AM for printing on freeform surfaces, which include weak interlayer bonding, lower surface finish, and high material requirement and printing time. This study explores the printability of the material and the feasibility of using this print process for manufacturing intricate and functional ceramic structures. The outcomes of this research may smooth the path toward more efficient and cost-effective manufacturing of advanced ceramics, thereby expanding their applicability in numerous industries.