Improved mechanical quality of ceramic vat photopolymerization prints by supercritical carbon dioxide extraction

IF 2.9 Q1 MATERIALS SCIENCE, CERAMICS

Open Ceramics Pub Date : 2025-02-15 DOI:10.1016/j.oceram.2025.100753

Nonna Nurmi , Erkka J. Frankberg , Arnold Ismailov , Dominique Hautcoeur , Setareh Zakeri , Essi Sarlin , Erkki Levänen

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Abstract

Vat photopolymerization (VPP) enables 3D printing of dense ceramics with complex structures, however the mandatory thermal pre-conditioning and debinding steps to remove the organic substances, can last 7 days. Supercritical carbon dioxide (scCO₂) extraction was used as a pre-conditioning method to investigate if dense and sufficiently strong alumina parts can be obtained using a shorter thermal debinding cycle, due to the creation of nanosized porosity during the scCO₂ extraction. The mechanical properties and microstructure of the sintered alumina parts with 15 h scCO₂ extraction + 18 h thermal debinding were comparable to the reference with 101 h debinding, which marks a significant 67 % reduction in time. Furthermore, scCO₂ extraction improved the flexural strength and density, and resulted in less deviation. Thus, scCO₂ extraction can shorten post-processing of ceramic VPP prints and facilitate more predictable properties, which have been the two bottlenecks related to the VPP process.

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