Ceramics and Composite Materials

The question to be answered by this research is, can a complex shaped ceramic part be manufactured successfully by combining 3D (additive manufacturing) and gelation casting techniques? A 3D printed mold was produced using ABS (Acrylonitrile Butadiene Styrene) filament which formed the negative of the part to be cast. Different gelation systems were used and the solids loading of the alumina ceramic powder in the gel were varied to optimize the systems viscosity. The alumina mixed with the gelation system was cast into the ABS printed molds. The parts were removed by dissolving the ABS mold in acetone. The combination of solids loading and gelation system had a significant influence on the sintered porosity and density of the final parts. An impeller shape was cast in this manner and achieved a density of 99% with an associated hardness of 18GPa. From the successful combining of 3D printing and gelation of alumina ceramic prior to sintering, components were manufactured with properties similar to alumina parts produced by classical processing methods.