A team from theFraunhofer Institute for Ceramic Technologies and Systems (IKTS)has developed a Multi Material Jetting (MMJ) system to combine multiple materials into a single additively manufactured part.
Based on thermoplastic binder systems, the new system utilizes high-performance materials such as ceramics and metal, combining different materials and their various properties into a single product.
“Right now, we can process up to four different materials at a time,” said Uwe Scheithauer, a researcher at Fraunhofer IKTS. This technology could enable companies to produce highly integrated multi-functional components with individual properties.
增材制造陶瓷
The early years of additive manufacturing were dominated by polymers, but this has since expanded to include metals and ceramic-based materials. One company at the forefront of this is binder jetting 3D printer manufacturer,ExOne, whose 3D printers arecapable of printing metals, ceramics, and composites，新材料连续合格。
Most recently, ExOne bestowed ‘Third Party Qualification’ status on itsIconel 718 nickel-based superalloy, typically used in high-stress aerospace, energy, and automotive applications, similar to the applications the Fraunhofer researchers believe their MMJ system would be suitable for. Iconel is characterized by its high strength, hardness, corrosion and chemical resistance, and excellent welding properties, as well as its ability to withstand extreme temperatures ranging from sub-zero to 700°C.
Across other sectors, 3D printing specialistLithoz的proprietary Lithography-based Ceramic Manufacturing (LCM) technique was recently used to3D print Corning glass ceramic materials陶瓷专家第一次3DCERAM-SINTOhasadvanced its ceramics 3D printing technologyto develop the next generation of medical X-ray imaging systems.
Fraunhofer IKTS’ new system
Fraunhofer’s MMJ system fabricates parts in a continuous process. Ceramic or metal powder from which the part will be made is uniformly distributed in a thermoplastic binder substance. The slurries produced from this are then loaded into micro-dosing systems (MDS) in order to commence the manufacturing process. The slurries are melted in the MDS at a temperature of around 100 degrees Celsius to create a substance that can be released in tiny droplets.
A corresponding software program developed by the researchers ensures the precise positioning of the droplets, which are deposited one by one via a high-precision, computer-controlled process. Gradually, the part is built up at rates of up to 60mm and 1,000 drops a second.
The system works with droplet sizes of between 300 and 1000 μm, creating deposited layers with heights of between 100 and 200 μm. The maximum size of parts that can currently be manufactured is 20 × 20 × 18 centimeters.
“这里的关键因素是定制的剂量the metal or ceramic slurries,” explained Scheithauer. “Getting the dosing right is key to ensuring that the additively manufactured final product takes on the required properties and functions during subsequent sintering in the furnace, including properties such as strength, thermal conductivity, and electrical conductivity.”
Potential applications
Fraunhofer研究人员应用IKTS系统的一个例子是制造高度复杂的部分，例如由陶瓷制成的卫星推进引擎中的点火系统。陶瓷承受热量的能力使它们成为卫星燃烧室的合适材料选择，达到极高的温度。
The ignition system combines both electrically conductive and insulating areas within a single component and requires three dosing systems: one for a support material that disintegrates during heat treatment in the furnace, a second for the electrically conductive component, and a third for the electrically insulating component.
根据研究人员的说法，MMJ还可以在消费产品市场中使用多种应用，并且由于其高精度和灵活性而不仅适合制造多功能组件。
“We could also use it to make blanks for carbide parts, for example,” said Scheithauer. “Thanks to the tremendous precision of the dosing systems, the contours of the blanks would already be very close to those of the end product. They would therefore require very little subsequent grinding as compared to conventional methods. That’s a big advantage when you are working with carbide.”
现在，Fraunhofer IKTS的项目已证明了实践中的技术工作，并且是可扩展的，下一步就是验证该技术以供商业使用。除了提供硬件外，Fraunhofer IKTS表示，它还可以帮助行业客户开发流程监控和自动化所需的材料和软件，这意味着他们可以从单个来源获得所需的一切。
Those interested in the technology can sign up for the onlineAM Ceramics meets CERAMITEC conference, taking place September 16-17.
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Featured image shows Fraunhofer IKTS’ system for Multi Material Jetting of high-performance components with combined properties or functions. Image via Fraunhofer IKTS.
