Additive manufacturing of composite glass/ceramic structures with self-similar geometries

The Hilbert curve fractal pattern was used to create a self-filling structure with designed porosity that would be ideal for applications such as biomedical components, circuit boards, and building materials. 3-Dimensional Hilbert curve structures were designed and analysed by Finite Element Analysis for various functions in fluid transport, heat transfer, and structural applications. A bespoke glass/zirconia composite paste was optimised for the fabrication of these structures by ceramic stereolithography, achieving a thixotropic photosensitive paste with a high solid loading of 69 %. Optimisation of process parameters and sintering schedule was carried out to allow accurate fabrication of the composite glass/zirconia structures. 3-Dimensional Hilbert curve structures were successfully fabricated by stereolithography and the designed structures have potential uses as highly efficient components in various industries.