The distinct characteristics of ceramics in terms of material preparation, processing and geometrical capabilities are setting limits on their performance and application potential. The use of water-soluble, 3D-printed moulds has established a hybrid manufacturing approach capable of producing freeform geometries with Ceramic Injection Molding (CIM). The single-cavity mould can offer the advantages of numerous design iterations at a reduced cost and lead times, with remarkable material versatility. We aim to expand the material portfolio from thermoplastic materials to customised ceramic feedstocks and different material formulations, aiming to produce functional ceramic parts for advanced applications. We examine the process capabilities of Freeform Injection Molding (FIM) in terms of geometrical complexity, quality of 3D structures and characterisation of functional piezoelectric properties in Pb-free ceramics.
To succeed with advanced ceramics, each process step needs to be compatible with the specific ceramic’s chemical composition and sintering mechanisms. The tolerance for defects introduced at any process step is extremely low for advanced ceramics. A general parameter space (particle size properties, demolding agents, binders) can be defined, to establish a successful process over a wide range of advanced ceramics with different chemistry and sintering requirements.
This project is carried out in collaboration between DTU Energy and Addifab ApS, has received funding from Innovation Fund Denmark and will be running from 01-04-2020 to 30-06-2023.
Main Supervisor: Prof. Vincenzo Esposito
Co-Supervisor: Assoc. Prof. Astri Bjørnetun Haugen