Direct-ink-writing 3D Printing of Ceramic-based Porous Structures: a Review

doi:10.15541/jim20230070

Abstract

Abstract:

Ceramic-based porous structures not only inherit the excellent properties of dense ceramic materials such as high-temperature resistance, electrical insulation, and chemical stability, but also have unique advantages similar to porous structures, including low density, high specific surface area, and low thermal conductivity. They show great potential in various applications, such as thermal insulation, bone tissue engineering, filtration and pollutants removal, and electronic components. However, there still exist some challenges for shaping complex geometries on the macro- scale and adjusting pore morphologies on the micro- and nano-scale through the conventional preparation strategy of ceramic-based porous structures. In recent decades, researchers have been devoting themselves to developing novel manufacturing techniques for ceramic-based porous structures. The direct-ink-writing 3D printing, as one of the representative additive manufacturing technologies, has become a current research hotspot, rapidly developing a series of mature theories and innovative methodologies for fabricating porous structures. In this work, the conventional strategies and additive manufacturing strategies for obtaining porous structures were firstly summarized. The direct-write assembly processes of pore structures were further introduced in detail, mainly including pseudoplastic ink formulation, solidification strategy, drying, and post-treatment. Meanwhile, the feasibility of direct-ink-writing 3D printing technologies combined with conventional manufacturing strategies in constructing ceramic-based hierarchical pore structures was analyzed emphatically. The new perspectives, developments, and discoveries of direct-ink-writing 3D printing technologies were further summarized in the field of manufacturing complex ceramic-based porous structures. In addition, the developments and challenges in the future were prospected according to the actual application status.

Key words: additive manufacturing, direct-ink-writing 3D printing, ceramic, porous material, functional application, review

CLC Number:

TQ174

WANG Lukai, FENG Junzong, JIANG Yonggang, LI Liangjun, FENG Jian. Direct-ink-writing 3D Printing of Ceramic-based Porous Structures: a Review[J]. Journal of Inorganic Materials, 2023, 38(10): 1133-1148.

Figures/Tables 13

Fig. 1 Complementarity of additive manufacturing and traditional processing for fabricating porous structures[4]

Fig. 2 Direct-ink-writing 3D printing technology (a) Schematic illustration of the ink extrusion process[29]; (b, c) Rheological behavior of pseudoplastic inks[28]

Table 1 Pore structure characteristics of representative ceramic-based porous structures and rheological properties and printing parameters of ink formulations

Fig. 3 Solidification strategies of ceramic-based inks (a) Solution-assisted solidification[61,63]; (b) Temperature-induced solidification[42,50]; (c) Light-based solidification[79]

Fig. 4 Parameter variation of temperature and pressure for different drying processes[28]

Fig. 5 Direct-ink-writing 3D printing technology integrated with direct foaming methods (a, b) Process schematic diagram of direct foam writing for porous ceramic-based structures[40]; (c-h) Morphologies of honeycomb ceramic with hierarchical pore structures[95]

Fig. 6 Direct-ink-writing 3D printing technology integrated with freezing casting method and its hierarchical porous alumina scaffold[70] (a) Schematic illustration of the printing process; (b) Microscopic morphology of hierarchical pore structures

Fig. 7 Direct-ink-writing 3D printing technology integrated with sacrificial template method (a, b) Flow chart of preparation of hierarchical porous SiOC ceramic structures[53]; (c) Three sacrificial template methods for 3D-printed ceramics[104]

Fig. 8 Direct-ink-writing 3D printing technology integrated with Sol-Gel method (a) Morphologies of hierarchical pore structures of SiO2 aerogels[105]; (b) TiO2 aerogel scaffolds with different hierarchical pore structures[61]

Fig. 9 3D-printed nanoporous ceramic-based aerogels for thermal insulation applications (a, b) Thermal shielding demonstration of 3D-printed Al2O3-SiO2 aerogels[42]; (c, d) 3D-printed SiO2 aerogels for miniaturized thermal insulation applications[105]

Fig. 10 3D-printed bioceramic scaffold and its implantation photographs of bone repair processes[112]

Fig. 11 3D-printed filters with hierarchical pore structures for sewage purification[115] (a) Direct-write assembly process; (b) Pollutant decomposition mechanism

Fig. 12 Structures, performances, and applications of 3D-printed porous piezoelectric ceramics (a-f) Printed structures and performance characterizations [51]; (g) Direct-ink-writing 3D printing processes of lead zirconate titanate piezoelectric ceramics[121]

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