Conformable green bodies: plastic forming of robocasted advanced ceramics

Abstract

Robocasting, or the additive manufacturing of ceramics by continuous extrusion of a ceramic paste, has limited capabilities when printing complex unsupported structures such as overhangs or free standing thin artefacts. In this paper we address this limitation using a new type of paste, which allows for shaping of the green bodies after printing. To illustrate the flexibility of the paste, it was used to produce both alumina and silicon carbide parts. The paste consists of a solution of phenolic resin in methyl ethyl ketone and ceramic powders. Fabricated parts can be cut, bent, folded and draped over various objects. Once dry and fully solid, the parts become rigid and can be processed further by slow pyrolysis and sintering. Sintered samples exhibit flexural strength comparable to both conventionally produced and robocasted ceramics and shaping of the green bodies after printing does not affect the mechanical strength of the sintered parts.