Additive Manufacturing of Ceramics

Zhangwei Chen, PhD, is a tenured professor and director of the Additive Manufacturing Institute at Shenzhen University, China, with 20 years of research in additive manufacturing of ceramics. He is a lifetime Fellow of the International Association of Advanced Materials, and is recognized among Stanford University’s Top 2% Global Scientists from 2021 to 2025. He has by now published around 200 papers with a Google scholar citation number reaching 10,000. Paolo Colombo is a professor of Materials Science and Technology at the University of Padova, Italy, and Adjunct Professor at Pennsylvania State University. He has published more than 400 peer-reviewed papers, holds 20 international patents, and served as President of the International Ceramic Federation. He is an elected Academician of the World Academy of Ceramics, European Academy of Sciences and Academia Europaea.

• Preface xiiiAbout the Editors xv1 Introduction 1Zhangwei Chen and Paolo Colombo1.1 Most Important Properties and Applications of Ceramics 21.2 Typical Processing Routes and Manufacturing Techniques for Ceramics 71.3 Challenges and the Need for Additive Manufacturing 91.4 Brief Introduction to Ceramic Additive Manufacturing Techniques 101.5 Summary of the book 141.6 Conclusions 182 Vat Photopolymerization (VPP) 25Vincent Pateloup and Gweni Alonso Aruffo2.1 Introduction 252.2 Photopolymerization 3D Printing Processes for Ceramic Parts 262.3 Process Modeling and Simulation 342.4 Advantages and Limits of VAT Processes 372.5 AM Hybridization Opportunities 392.6 Next Generation Ceramic Printing: Two-Photon Photopolymerization and Volumetric Additive Manufacturing Methods 412.7 Conclusion 453 Binder Jetting (BJT) and Material Jetting (MJT) 51Andrea Zocca, Jens Günster, Anna-Katharina Hofer, and Stefan Waldner3.1 Inkjet Printing 513.2 Binder Jetting (BJT) 623.3 Material Jetting 843.4 Post-Processes 984 Material Extrusion (MEX) 109Frank Clemens and Esther García-Tuñón4.1 Introduction 1094.2 Direct InkWriting 1094.3 Fused Filament Fabrication 1244.4 Heat Treatment and Post-Processing 1314.5 AM of Fiber-Reinforced Composites 1354.6 Summary 1395 Powder-Bed Fusion (PBF) 153Enrique Juste and Fabrice Petit5.1 Short Historical Background of PBF 1545.2 Terminology Focus 1555.3 Indirect – Powder-Bed-Selective Laser Processing (PBSLP) 1575.4 Direct – Powder-Bed-Selective Laser Processing (PBSLP) 1615.5 Process Parameters PBF 1715.6 Heat Treatment and Post-Processing 1825.7 Conclusion 1856 Directed Energy Deposition (DED) 195Amit Bandyopadhyay, Nathaniel W. Zuckschwerdt, and Susmita Bose6.1 Introduction 1956.2 Advantages and Limitations of DED 1976.3 Powder Characteristics 1996.4 DED Processing-Related Challenges 2006.5 Processing via DED 2016.6 Monolithic Ceramics 2016.7 Metal-Matrix Composites via DED 2036.8 Current Challenges and Future Directions 2066.9 Summary 2077 Hybrid AM of Ceramics and AM of Ceramic-Based Multi-Material Components 211Giorgia Franchin, Uwe Scheithauer, and Tassilo Moritz7.1 Hybrid Additive Manufacturing of Ceramics 2117.2 Sequential Hybrid Processes 2147.3 Additive Manufacturing of Ceramic-Based Multi-Material Components 2177.4 Applications 2277.5 Conclusion and Outlook for AM of Ceramic Multi-Material Components 2308 Design and Characterization of Additively Manufactured Ceramics 243Riccardo Balzarotti, Marco Pelanconi, Giovanni Bianchi, and Alberto Ortona8.1 Introduction 2438.2 Model Design – General Rules for Ceramic AM 2438.3 Topological Optimization and Numerical Simulation 2448.4 Characterization of the Feedstocks Prior to Printing 2458.5 Characterization of the Parts Before and After Heat Processing 2528.6 Summary 2599 Industrial VPP Equipment for AM of Functional Ceramic Composites 269Martin Schwentenwein, Serkan Nohut, and Johannes Homa9.1 Introduction 2699.2 Materials and Rheology 2709.3 Processing 2709.4 Reproducibility 2719.5 Quality Management, Compliance, and Performance Metrics 2719.6 Economic and Regulatory Considerations 2739.7 Industrial Applications of Lithography-Based Ceramic AM 2739.8 Market Considerations and Selection Guidance 2749.9 Multi-Material Additive Manufacturing 2759.10 Multi-Material AM of Ceramic Composites with LCM 2769.11 Applications for LCM Multi-Material Printing 2799.12 Future Research 2869.13 Summary 28810 Applications and Impacts of AM of Ceramics 295Kareen Malsallez, Maxence Bourjol, Natalia Kostretsova, Marc Torrell, Albert Tarancón, Malte Hartmann, Johannes Noll, Georgia Astbury, Matthew Drane, and Elsa Antunes10.1 Aerospace and Defense Applications 29610.2 Chemical Applications 29810.3 Electronic and Semiconductor Applications 29910.4 Biomedical Applications 30110.5 Detailed Case Studies of Ceramic AM Applications 30610.6 Cross-Domain Value and Systemic Impact of Ceramic Additive Manufacturing 31510.7 Conclusion 31811 New Developments and Perspectives 321Fiona Spirrett and Soshu Kirihara11.1 Introduction 32111.2 Green/Smart Design and Manufacturing 32211.3 4D/5D Printing 32811.4 Potentials and Challenges 336References 338Index 341