Evaluating geometric conformity and compressive properties of black zirconia gyroid structures obtained through fused filament fabrication.
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| Title: | Evaluating geometric conformity and compressive properties of black zirconia gyroid structures obtained through fused filament fabrication. |
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| Authors: | Justino Netto, Joaquim1 (AUTHOR) joaquim.netto@tecnico.ulisboa.pt, Sardinha, Manuel1 (AUTHOR), Leite, Marco1 (AUTHOR) |
| Source: | International Journal of Advanced Manufacturing Technology. May2025, Vol. 138 Issue 3, p1143-1157. 15p. |
| Subjects: | Ceramic engineering, Ceramic materials, X-ray computed microtomography, Unit cell, Cell size |
| Abstract: | Additive manufacturing (AM) of ceramics is gaining prominence due to its potential to produce structures with exceptional mechanical, thermal, and electrical properties that are otherwise difficult to achieve. Among the various ceramic 3D printing methods, fused filament fabrication (FFF) has drawn significant research attention for its simplicity and accessible equipment. However, fabricating ceramic green parts from highly filled filaments poses challenges, especially in process tuning and handling complex geometries. While much research has focused on preceramic filament formulations, process feasibility, and bulk mechanical properties, the capacity of FFF to produce intricate ceramic shapes, such as gyroids, remains underexplored. This study investigates the fabrication of gyroid lattice structures with different unit cell sizes and wall thicknesses using a commercial black zirconia filament. The quality of the printed parts was evaluated at different production stages using digital microscopy, precision weighting, micro-computed tomography (micro-CT) scanning, and compression testing. Microscope analysis revealed surface quality deterioration with increased structural complexity, particularly in designs with smaller cells and thinner walls, while larger cells and thinner walls led to more severe wall holes. Weight measurements indicated less material than expected, though material accumulations in more complex lattices compensated for some loss. Micro-CT scanning identified distortions, especially in designs with larger cells and thicker walls. In addition, it was found that the prescribed wall thicknesses were not achieved. Compression testing revealed brittle failure, with cell size having a more significant impact on properties than wall thickness. For high specific properties, smaller-cell designs with thicker walls are recommended, despite potential defects. [ABSTRACT FROM AUTHOR] |
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| Database: | Engineering Source |
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| Abstract: | Additive manufacturing (AM) of ceramics is gaining prominence due to its potential to produce structures with exceptional mechanical, thermal, and electrical properties that are otherwise difficult to achieve. Among the various ceramic 3D printing methods, fused filament fabrication (FFF) has drawn significant research attention for its simplicity and accessible equipment. However, fabricating ceramic green parts from highly filled filaments poses challenges, especially in process tuning and handling complex geometries. While much research has focused on preceramic filament formulations, process feasibility, and bulk mechanical properties, the capacity of FFF to produce intricate ceramic shapes, such as gyroids, remains underexplored. This study investigates the fabrication of gyroid lattice structures with different unit cell sizes and wall thicknesses using a commercial black zirconia filament. The quality of the printed parts was evaluated at different production stages using digital microscopy, precision weighting, micro-computed tomography (micro-CT) scanning, and compression testing. Microscope analysis revealed surface quality deterioration with increased structural complexity, particularly in designs with smaller cells and thinner walls, while larger cells and thinner walls led to more severe wall holes. Weight measurements indicated less material than expected, though material accumulations in more complex lattices compensated for some loss. Micro-CT scanning identified distortions, especially in designs with larger cells and thicker walls. In addition, it was found that the prescribed wall thicknesses were not achieved. Compression testing revealed brittle failure, with cell size having a more significant impact on properties than wall thickness. For high specific properties, smaller-cell designs with thicker walls are recommended, despite potential defects. [ABSTRACT FROM AUTHOR] |
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| ISSN: | 02683768 |
| DOI: | 10.1007/s00170-025-15575-y |
