A digitally-driven Hybrid Manufacturing process for the flexible production of engineering ceramic components

David Flynn, Robert W. Kay, Russell A. Harris, Jack Hinton

Research output: Chapter in Book/Report/Conference proceedingConference contribution

Abstract

Predominant techniques for manufacturing ceramic components use template-driven methods, which hampers responsiveness and impose significant design constraints. This has driven significant interest towards using additive manufacturing approaches. When used in isolation these techniques are restricted by uncontrollable porosity, high shrinkages during firing plus a lack of process-compatible materials. This paper presents the research and development of a new hybrid manufacturing process chain for the agile production of engineering grade ceramics components. The combination of high viscosity ceramic paste extrusion, sacrificial support deposition and subtractive micro-machining has yielded complex monolithic ceramic components with feature sizes of XX, part densities of ~99.7%, surface roughness down to ~1µm Ra and 3-point bend strength of 218MPa. Since a wide range of materials can be formulated into visco-elastic pastes they can be readily deposited using this approach.
Original languageEnglish
Title of host publicationProceedings of the 29th Annual International Solid Freeform Fabrication Symposium
Publication statusAccepted/In press - 4 Jun 2018
Event29th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference - Hilton Austin Hotel, Austin, United States
Duration: 13 Aug 201815 Aug 2018
http://www.programmaster.org/PM/PM.nsf/ApprovedAbstracts/17612F7D954B1DDA85258271004D874B?OpenDocument

Conference

Conference29th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference
CountryUnited States
CityAustin
Period13/08/1815/08/18
Internet address

Fingerprint

3D printers
Extrusion
Machining
Porosity
Surface roughness
Viscosity

Keywords

  • manufacturing
  • Digital
  • Ceramics
  • component

Cite this

Flynn, D., Kay, R. W., Harris, R. A., & Hinton, J. (Accepted/In press). A digitally-driven Hybrid Manufacturing process for the flexible production of engineering ceramic components. In Proceedings of the 29th Annual International Solid Freeform Fabrication Symposium
Flynn, David ; Kay, Robert W. ; Harris, Russell A. ; Hinton, Jack. / A digitally-driven Hybrid Manufacturing process for the flexible production of engineering ceramic components. Proceedings of the 29th Annual International Solid Freeform Fabrication Symposium. 2018.
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abstract = "Predominant techniques for manufacturing ceramic components use template-driven methods, which hampers responsiveness and impose significant design constraints. This has driven significant interest towards using additive manufacturing approaches. When used in isolation these techniques are restricted by uncontrollable porosity, high shrinkages during firing plus a lack of process-compatible materials. This paper presents the research and development of a new hybrid manufacturing process chain for the agile production of engineering grade ceramics components. The combination of high viscosity ceramic paste extrusion, sacrificial support deposition and subtractive micro-machining has yielded complex monolithic ceramic components with feature sizes of XX, part densities of ~99.7{\%}, surface roughness down to ~1µm Ra and 3-point bend strength of 218MPa. Since a wide range of materials can be formulated into visco-elastic pastes they can be readily deposited using this approach.",
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Flynn, D, Kay, RW, Harris, RA & Hinton, J 2018, A digitally-driven Hybrid Manufacturing process for the flexible production of engineering ceramic components. in Proceedings of the 29th Annual International Solid Freeform Fabrication Symposium. 29th Annual International Solid Freeform Fabrication Symposium - An Additive Manufacturing Conference, Austin, United States, 13/08/18.

A digitally-driven Hybrid Manufacturing process for the flexible production of engineering ceramic components. / Flynn, David; Kay, Robert W.; Harris, Russell A.; Hinton, Jack.

Proceedings of the 29th Annual International Solid Freeform Fabrication Symposium. 2018.

Research output: Chapter in Book/Report/Conference proceedingConference contribution

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N2 - Predominant techniques for manufacturing ceramic components use template-driven methods, which hampers responsiveness and impose significant design constraints. This has driven significant interest towards using additive manufacturing approaches. When used in isolation these techniques are restricted by uncontrollable porosity, high shrinkages during firing plus a lack of process-compatible materials. This paper presents the research and development of a new hybrid manufacturing process chain for the agile production of engineering grade ceramics components. The combination of high viscosity ceramic paste extrusion, sacrificial support deposition and subtractive micro-machining has yielded complex monolithic ceramic components with feature sizes of XX, part densities of ~99.7%, surface roughness down to ~1µm Ra and 3-point bend strength of 218MPa. Since a wide range of materials can be formulated into visco-elastic pastes they can be readily deposited using this approach.

AB - Predominant techniques for manufacturing ceramic components use template-driven methods, which hampers responsiveness and impose significant design constraints. This has driven significant interest towards using additive manufacturing approaches. When used in isolation these techniques are restricted by uncontrollable porosity, high shrinkages during firing plus a lack of process-compatible materials. This paper presents the research and development of a new hybrid manufacturing process chain for the agile production of engineering grade ceramics components. The combination of high viscosity ceramic paste extrusion, sacrificial support deposition and subtractive micro-machining has yielded complex monolithic ceramic components with feature sizes of XX, part densities of ~99.7%, surface roughness down to ~1µm Ra and 3-point bend strength of 218MPa. Since a wide range of materials can be formulated into visco-elastic pastes they can be readily deposited using this approach.

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Flynn D, Kay RW, Harris RA, Hinton J. A digitally-driven Hybrid Manufacturing process for the flexible production of engineering ceramic components. In Proceedings of the 29th Annual International Solid Freeform Fabrication Symposium. 2018