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High-Precision Printing of Cermets by Collapsable Matrix Assisted Digital Light Processing.

Yupeng Shan¹, Zhi Zhao¹, Haibin Wang¹

¹Key Laboratory of Advanced Functional Materials, Education Ministry of China, College of Material Science and Engineering, Beijing University of Technology, Beijing, 100124, China.

Small (Weinheim an Der Bergstrasse, Germany)

|August 16, 2024

Summary

A novel collapsable matrix enables Digital Light Processing (DLP) to precisely 3D print tungsten carbide-cobalt (WC-Co) cermets. This breakthrough overcomes material light absorption challenges, achieving high resolution and complex structures for advanced manufacturing.

Keywords:

additive manufacturing collapsable matrix composite materials digital light processing high‐precision

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Area of Science:

Materials Science
Additive Manufacturing
Nanotechnology

Background:

Shaping hard and brittle materials like cermets at micrometer resolution is challenging for traditional machining and additive manufacturing.
Digital Light Processing (DLP) is limited in printing cermet precursors due to high optical absorption by powder particles.

Purpose of the Study:

To develop an innovative protocol for high-precision additive manufacturing of WC-Co cermets using DLP.
To overcome the limitations of DLP in processing highly light-attenuating materials.

Main Methods:

A versatile collapsable matrix was designed to manage composite powder properties during DLP printing.
The matrix attenuates powders to enable photopolymerization and then shrinks to condense green parts before sintering.

Main Results:

Achieved ≈90% relative density and a record-breaking resolution of ≈10 µm for WC-Co cermets.
Fabricated complex structures like micro-drills with a microhardness of up to 14.5 GPa.
Demonstrated direct usability of the 3D printed micro-drill for practical applications.

Conclusions:

The collapsable matrix strategy successfully enables high-resolution DLP printing of light-attenuating cermet materials.
This advancement opens new possibilities for next-generation ceramic-metal composite additive manufacturing.
The technique allows for the direct fabrication of intricate and functional micro-parts.