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Method for Attaining Dimensionally Accurate Conditions for High-Resolution Three-Dimensional Printing Ceramic

Henry Oliver T Ware1, Cheng Sun1

  • 1Department of Mechanical Engineering, Northwestern University, 2145 Sheridan Rd. Rm. B224, Evanston, IL 60208.

Journal of Micro- and Nano-Manufacturing
|July 14, 2022
PubMed
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We optimized ceramic 3D printing using micro-Continuous Liquid Interface Production (CLIP) by balancing UV light scattering and oxygen effects. This allows for faster, high-resolution fabrication of complex ceramic parts.

Area of Science:

  • Materials Science
  • Additive Manufacturing
  • Optical Engineering

Background:

  • Continuous Liquid Interface Production (CLIP) enables rapid 3D printing by using projection ultraviolet (UV) light and oxygen inhibition.
  • Incorporating ceramic particles into photocurable polymers allows for complex ceramic part fabrication.
  • Ceramic particle scattering of UV light in microCLIP alters feature dimensions and curing depth, complicating process control.

Purpose of the Study:

  • To develop a systematic framework for optimizing microCLIP process parameters for ceramic inks.
  • To balance the competing effects of UV light scattering and oxygen deadzone thickness.
  • To achieve high-resolution 3D fabrication of ceramic components with dimensional accuracy.

Main Methods:

  • Experimental characterization of UV light scattering and oxygen deadzone thickness in microCLIP.

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  • Development of a systematic framework to optimize UV power and stage speed.
  • Validation of the optimization method through fabricating a gradient index Luneburg lens.

    • Main Results:

    • Identified optimal process parameters (UV power, stage speed) for high-resolution ceramic 3D printing.
    • Demonstrated control over feature dimensions and curing depth despite ceramic particle scattering.
    • Successfully fabricated a complex Luneburg lens with 100 μm strut width and 60 μm layer thickness.

    Conclusions:

    • The developed optimization framework effectively manages microCLIP process variations caused by ceramic inks.
    • This approach enables precise, high-resolution 3D printing of advanced ceramic materials.
    • Optimized microCLIP is a viable method for fabricating intricate ceramic structures for various applications.