Study of 3D printing process: Optimization, quality analysis, and comparison of 3D printed and cast ceramic properties

Abstract

The goal of this study was to optimize and validate the procedures and methods used to form ceramic objects using 3D-print molding instead of cast molding. Chamotte refractory clay was shaped into 5 x 5 x 5 cm cubes using both the 3D-print-molding and cast-molding methods. These cubes were then evaluated, fired, and evaluated again. The 3D-print molding method used was an adaptation of ’direct ink writing’. Since refractory clay dries during manufacturing, a Photoneo 3D scanner was used to monitor cube shrinkage before firing. Other basic properties such as mineralogical composition, evaluated via X-ray diffraction, were also measured. X-ray fluorescence spectroscopy determined chemical composition. After firing, compressive strength, bulk density, porosity, and water absorption were measured and structural aspects such as cracking and porosity were evaluated. The 3D-print molding of the chamotte clay was largely successful. The measured compressive strength of the fired 3D-print-molded and cast-molded ceramic cubes was 31.4 MPa and 30.4 MPa, respectively. The 3D-print-molded ceramic parts were slightly more porous (14.5%) and absorptive (7.1%). Total volumetric shrinkage was 36 %. Detailed cross-sectional analysis of the samples identified defects related to specific shortcomings of both molding methods. This information suggests areas that could be targeted for refinement. Addressing them could lead to significant advancements, allowing 3D-print-molded ceramics and similar materials to achieve superior properties compared to conventional manufacturing methods.