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Additive manufacturing has been an enormous development in the last three decades, and it has found its way into many industrial applications with significant impact and opportunities. Among all AM processes, DIW (Robocasting) is a cost-effective method of developing products using direct ink extrusion layer-by-layer, consisting of ceramics, biomaterials, polymers, and other colloidal pastes. Due to the excellent combination of mechanical, thermal, chemical, and physical properties of ceramics, AM of ceramics is gaining more and more exploration in academics and Manufacturing organizations. It can produce complex structures and scaffolds and find use in various industries, including microelectronics and biological tissue engineering. In the present work, Direct extrusion of terracotta clay has been done with the help of a modified setup to form various complex shapes, and parameters like layer height, printing speed, and nozzle diameter have been optimized for better surface properties. The flexural strength of the clay has been improved by dispersing Graphite powder and metal powders of Aluminum, Copper respectively. Solid volume fractions of 30, 40, 50, and 60% have been used to print the product, and the effect of various parameters has been discussed in detail. Slumping of the printed strands occurs as the solid volume fraction is low, which makes the object unable to maintain its shape. Clogging occurs when the solid fraction is more and the paste cannot be extruded from the nozzle despite applying pressure. The present work discusses the different solid volume fractions and their effect on the final product. The effect of sintering temperature on the density of the final part has been analyzed. Clay with optimized water content showed excellent flowability and shape retention after Printing. Layer thickness during Printing affected the surface properties. Strength improved after dispersing graphite and metal powders. The present study highlights manufacturing complex clay parts for pottery and artifacts applications.

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3D Printing of Clay Ceramics Using Direct Ink Writing (DIW) Technique

  • 会议论文

  • 发表日期：

    2025年

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  • Pankaj Bothra,
  • Sankata Tiwari,
  • Santosh Kumar,
  • Govind Kumar Verma

摘要

Additive manufacturing has been an enormous development in the last three decades, and it has found its way into many industrial applications with significant impact and opportunities. Among all AM processes, DIW (Robocasting) is a cost-effective method of developing products using direct ink extrusion layer-by-layer, consisting of ceramics, biomaterials, polymers, and other colloidal pastes. Due to the excellent combination of mechanical, thermal, chemical, and physical properties of ceramics, AM of ceramics is gaining more and more exploration in academics and Manufacturing organizations. It can produce complex structures and scaffolds and find use in various industries, including microelectronics and biological tissue engineering. In the present work, Direct extrusion of terracotta clay has been done with the help of a modified setup to form various complex shapes, and parameters like layer height, printing speed, and nozzle diameter have been optimized for better surface properties. The flexural strength of the clay has been improved by dispersing Graphite powder and metal powders of Aluminum, Copper respectively. Solid volume fractions of 30, 40, 50, and 60% have been used to print the product, and the effect of various parameters has been discussed in detail. Slumping of the printed strands occurs as the solid volume fraction is low, which makes the object unable to maintain its shape. Clogging occurs when the solid fraction is more and the paste cannot be extruded from the nozzle despite applying pressure. The present work discusses the different solid volume fractions and their effect on the final product. The effect of sintering temperature on the density of the final part has been analyzed. Clay with optimized water content showed excellent flowability and shape retention after Printing. Layer thickness during Printing affected the surface properties. Strength improved after dispersing graphite and metal powders. The present study highlights manufacturing complex clay parts for pottery and artifacts applications.