Ceramic Robocasting: Recent Achievements, Potential, and Future Developments

Processing, Microstructure, and Performance of Robocast Clay-Based Ceramics Incorporating Hollow Alumina Microspheres

The restoration of ancient ceramics has attracted widespread attention as it can reveal the overall appearance of ancient ceramics as well as the original information and artistic charm of cultural relics. However, traditional manual restoration is constrained due to its time-consuming nature and susceptibility to damaging ancient ceramics. Herein, a three-dimensional (3D) printing technique was employed to accurately restore Chinese Yuan Dynasty Longquan celadon using hollow Al2O3 microsphere-modified 3D printing paste. The results show that the hollow Al2O3 microsphere content plays a vital role in the printability, physical properties, and firing performance of the modified 3D printing paste. The printed green bodies show no noticeable spacing or voids under moderate rheological conditions. The as-prepared ceramic body modified with 6 wt.% hollow Al2O3 microspheres and fired at 1280 °C exhibits optimal bending strength of 56.66 MPa and a relatively low density of 2.16 g∙cm-3, as well as a relatively uniform longitudinal elastic modulus and hardness along the interlayer. This 3D printing technique based on hollow Al2O3 microsphere-modified paste presents a promising pathway for achieving non-contact and damage-free restoration of cultural relics.

UV-Curing Assisted Direct Ink Writing of Dense, Crack-Free, and High-Performance Zirconia-Based Composites With Aligned Alumina Platelets

Additive manufacturing (AM) of high-performance structural ceramic components with comparative strength and toughness as conventionally manufactured ceramics remains challenging. Here, a UV-curing approach is integrated in direct ink writing (DIW), taking advantage from DIW to enable an easy use of high solid-loading pastes and multi-layered materials with compositional changes; while, avoiding drying problems. UV-curable opaque zirconia-based slurries with a solid loading of 51 vol% are developed to fabricate dense and crack-free alumina-toughened zirconia (ATZ) containing 3 wt% alumina platelets. Importantly, a non-reactive diluent is added to relieve polymerization-induced internal stresses, avoid subsequent warping and cracking, and facilitate the de-binding. For the first time, UV-curing assisted DIW-printed ceramic after sintering reveals even better mechanical properties than that processed by a conventional pressing. This is attributed to the aligned alumina platelets, enhancing crack deflection and improving the fracture toughness from 6.8 ± 0.3 MPa m0.5 (compacted) to 7.4 ± 0.3 MPa m0.5 (DIW). The four-point bending strength of the DIW ATZ (1009 ± 93 MPa) is also higher than that of the conventionally manufactured equivalent (861 ± 68 MPa). Besides homogeneous ceramic, laminate structures are demonstrated. This work provides a valuable hybrid approach to additively manufacture tough and strong ceramic components.

The Effect of Temperature and Shear on the Gelation of Cellulose Nanocrystals in Deep Eutectic Solvents

With the flourishing development of 3D printing technology, the demand for printing materials has been increasing rapidly in recent years. In particular, physical gels formed by cellulose nanocrystals (CNCs) exhibit suitable shear-thinning behavior, high storage moduli, and high yield stresses for extrusion-based printing. While most studies use water as the dispersing medium to form CNC percolated gels, the dispersing behavior of CNCs in alternative solvents, such as deep eutectic solvents (DESs), has not been fully explored. Especially, DESs have low volatility and good ionic conductivity to form functional ionogels. Precise control of the rheological properties and selection of suitable dispersion processes continue to pose significant challenges. In light of this, we have devised a novel dispersion process employing thermal and shear treatments to facilitate the gelation of CNCs within DESs. A crude dispersion of CNCs in the DES underwent thermal treatment to partially remove the surface sulfate ester on CNCs. As a result, the repulsive force between CNCs decreases. A second shear then significantly increases the strength of CNC/DES gels potentially because of the increased rod-rod contacts. This approach enables the formation of high-strength gels at low concentrations of CNCs. Both thermal treatment and a second shear are crucial to forming strong percolated CNC gels. In short, we showed a simple strategy to facilitate the dispersion and gelation of CNCs for direct ink writing.

3D printed zirconia used as dental materials: a critical review

In view of its high mechanical performance, outstanding aesthetic qualities, and biological stability, zirconia has been widely used in the fields of dentistry. Due to its potential to produce suitable advanced configurations and structures for a number of medical applications, especially personalized created devices, ceramic additive manufacturing (AM) has been attracting a great deal of attention in recent years. AM zirconia hews out infinite possibilities that are otherwise barely possible with traditional processes thanks to its freedom and efficiency. In the review, AM zirconia's physical and adhesive characteristics, accuracy, biocompatibility, as well as their clinical applications have been reviewed. Here, we highlight the accuracy and biocompatibility of 3D printed zirconia. Also, current obstacles and a forecast of AM zirconia for its development and improvement have been covered. In summary, this review offers a description of the basic characteristics of AM zirconia materials intended for oral medicine. Furthermore, it provides a generally novel and fundamental basis for the utilization of 3D printed zirconia in dentistry.

A 3D-Printed Ceramics Innovative Firing Technique: A Numerical and Experimental Study

Additive manufacturing (AM), also known as three-dimensional (3D) printing, allows the fabrication of complex parts, which are impossible or very expensive to produce using traditional processes. That is the case for dinnerware and artworks (stoneware, porcelain and clay-based products). After the piece is formed, the greenware is fired at high temperatures so that these pieces gain its mechanical strength and aesthetics. The conventional (gas or resistive heating elements) firing usually requires long heating cycles, presently requiring around 10 h to reach temperatures as high as 1200 °C. Searching for faster processes, 3D-printed stoneware were fired using microwave (MW) radiation. The pieces were fired within 10% of the conventional processing time. The temperature were controlled using a pyrometer and monitored using Process Temperature Control Rings (PTCRs). An error of 1.25% was calculated between the PTCR (1207 ± 15 °C) and the pyrometer (1200 °C). Microwave-fast-fired pieces show similar mechanical strength to the references and to the electrically fast-fired pieces (41, 46 and 34 (N/mm2), respectively), presenting aesthetic features closer to the reference. Total porosities of ~4%, ~5% and ~9% were determined for microwave, electrically fast-fired and reference samples. Numerical studies have shown to be essential to better understand and improve the firing process using microwave radiation. In summary, microwave heating can be employed as an alternative to stoneware conventional firing methods, not compromising the quality and features of the processed pieces, and with gains in the heating time.

3D printing in materials manufacturing industry: A realm of Industry 4.0

Additive manufacturing (AM), also known as 3D printing, is a new manufacturing trend showing promising progress over time in the era of Industry 4.0. So far, various research has been done for increasing the reliability and productivity of a 3D printing process. In this regard, reviewing the existing concepts and forwarding novel research directions are important. This paper reviews and summarizes the process flow, technologies, configurations, and monitoring of AM. It started with the general AM process flow, followed by the definitions and the working principles of various AM technologies and the possible AM configurations, such as traditional and robot-assisted AM. Then, defect detection, fault diagnosis, and open-loop and closed-loop control systems in AM are discussed. It is noted that introducing robots into the assisting mechanism of AM increases the reliability and productivity of the manufacturing process. Moreover, integrating machine learning and conventional control algorithms ensures a closed-loop control in AM, a promising control strategy. Lastly, the paper addresses the challenges and future trends.

3D Printing of Copper Using Water-Based Colloids and Reductive Sintering

Copper was manufactured by using a low-cost 3D printing device and copper oxide water-based colloids. The proposed method avoids the use of toxic volatile solvents (used in metal-based robocasting), adopting copper oxide as a precursor of copper metal due to its lower cost and higher chemical stability. The appropriate rheological properties of the colloids have been obtained through the addition of poly-ethylene oxide-co-polypropylene-co-polyethylene oxide copolymer (Pluronic P123) and poly-acrylic acid to the suspension of the oxide in water. Mixing of the components of the colloidal suspension was performed with the same syringes used for the extrusion, avoiding any material waste. The low-temperature transition of water solutions of P123 is used to facilitate the homogenization of the colloid. The copper oxide is then converted to copper metal through a reductive sintering process, performed at 1000°C for a few hours in an atmosphere of Ar-10%H2. This approach allows the obtainment of porous copper objects (up to 20%) while retaining good mechanical properties. It could be beneficial for many applications, for example current collectors in lithium batteries.

3D printing of unsupported multi-scale and large-span ceramic via near-infrared assisted direct ink writing

In the three-dimensional printing process of ceramic with low-angle structures, additional supporting structures are usually employed to avoid collapse of overhanging parts. However, the extra supporting structures not only affect printing efficiency, but the problems caused by their removal are also a matter of concern. Herein, we present a ceramic printing method, which can realize printing of unsupported multi-scale and large-span ceramics through the combination of direct ink writing and near-infrared induced up-conversion particles-assisted photopolymerization. This printing technology enables in-situ curing of multi-scale filaments with diameters ranging from 410 µm to 3.50 mm, and ceramic structures of torsion spring, three-dimensional bending and cantilever beam were successfully constructed through unsupported printing. This method will bring more innovation to the unsupported 3D manufacturing of complex shape ceramics.

Advances in the Synthesis of Preceramic Polymers for the Formation of Silicon-Based and Ultrahigh-Temperature Non-Oxide Ceramics

Preceramic polymers (PCPs) are a group of specialty macromolecules that serve as precursors for generating inorganics, including ceramic carbides, nitrides, and borides. PCPs represent interesting synthetic challenges for chemists due to the elements incorporated into their structure. This group of polymers is also of interest to engineers as PCPs enable the processing of polymer-derived ceramic products including high-performance ceramic fibers and composites. These finished ceramic materials are of growing significance for applications that experience extreme operating environments (e.g., aerospace propulsion and high-speed atmospheric flight). This Review provides an overview of advances in the synthesis and postpolymerization modification of macromolecules forming nonoxide ceramics. These PCPs include polycarbosilanes, polysilanes, polysilazanes, and precursors for ultrahigh-temperature ceramics. Following our review of PCP synthetic chemistry, we provide examples of the application and processing of these polymers, including their use in fiber spinning, composite fabrication, and additive manufacturing. The principal objective of this Review is to provide a resource that bridges the disciplines of synthetic chemistry and ceramic engineering while providing both insights and inspiration for future collaborative work that will ultimately drive the PCP field forward.

3D-printed β-TCP/S53P4 bioactive glass scaffolds coated with tea tree oil: Coating optimization, in vitro bioactivity and antibacterial properties

Bone infection treatment is a significant challenge for the orthopedic field. 3D printing is a promising technology to produce scaffolds with customized architecture, able to stimulate and support bone growth. β-TCP and S53P4 bioactive glass (BG) are well-known biomaterials for scaffold manufacturing. However, a multifunctional scaffold, able to inhibit microbial proliferation at the defect site, is of increasing interest to avoid infection recurrence. Tea tree oil (TTO) has aroused interest as an antimicrobial agent to minimize the use of antibiotics. Therefore, combining the regenerative potential of a bioceramic with TTO's antimicrobial properties could result in a scaffold capable of stimulating tissue growth and treating infections. In this context, this study aimed to produce and characterize 3D-printed β-TCP/S53P4 BG scaffolds coated with TTO. Scaffolds morphological and chemical characterizations were carried out through XDR, SEM, and FTIR analysis. β-TCP/S53P4 BG scaffolds showed a compressive strength of ~2 MPa and 53 ± 2% of porosity. The scaffolds were coated by two different procedures, using an ethanol/TTO (EtOH/TTO) and a gelatin/TTO (Gel/TTO) solution with 5, 10, and 15% (v/v) TTO. The addition of TTO decreased MG-63 cell viability for both coating groups, but the Gel/TTO group showed higher cell viability. The antibacterial activity of the coated scaffolds was evaluated against S. aureus and higher inhibition of colony formation was found for Gel/TTO group. Therefore, the coating with Gel/TTO was effective in terms of antibacterial activity and cell viability. Such Gel/TTO coated β-TCP/S53P4 BG scaffolds are proposed for antibacterial bone tissue engineering.

Embedded 3D Printing of Architected Ceramics via Microwave-Activated Polymerization

Light- and ink-based 3D printing methods have vastly expanded the design space and geometric complexity of architected ceramics. However, light-based methods are typically confined to a relatively narrow range of preceramic and particle-laden resins, while ink-based methods are limited in geometric complexity due to layerwise assembly. Here, embedded 3D printing is combined with microwave-activated curing to generate architected ceramics with spatially controlled composition in freeform shapes. Aqueous colloidal inks are printed within a support matrix, rapidly cured via microwave-activated polymerization, and subsequently dried and sintered into dense architectures composed of one or more oxide materials. This integrated manufacturing method opens new avenues for the design and fabrication of complex ceramic architectures with programmed composition, density, and form for myriad applications.

Bioceramic scaffolds with triply periodic minimal surface architectures guide early-stage bone regeneration

The pore architecture of porous scaffolds is a critical factor in osteogenesis, but it is a challenge to precisely configure strut-based scaffolds because of the inevitable filament corner and pore geometry deformation. This study provides a pore architecture tailoring strategy in which a series of Mg-doped wollastonite scaffolds with fully interconnected pore networks and curved pore architectures called triply periodic minimal surfaces (TPMS), which are similar to cancellous bone, are fabricated by a digital light processing technique. The sheet-TPMS pore geometries (s-Diamond, s-Gyroid) contribute to a 3‒4-fold higher initial compressive strength and 20%-40% faster Mg-ion-release rate compared to the other-TPMS scaffolds, including Diamond, Gyroid, and the Schoen's I-graph-Wrapped Package (IWP) in vitro. However, we found that Gyroid and Diamond pore scaffolds can significantly induce osteogenic differentiation of bone marrow mesenchymal stem cells (BMSCs). Analyses of rabbit experiments in vivo show that the regeneration of bone tissue in the sheet-TPMS pore geometry is delayed; on the other hand, Diamond and Gyroid pore scaffolds show notable neo-bone tissue in the center pore regions during the early stages (3-5 weeks) and the bone tissue uniformly fills the whole porous network after 7 weeks. Collectively, the design methods in this study provide an important perspective for optimizing the pore architecture design of bioceramic scaffolds to accelerate the rate of osteogenesis and promote the clinical translation of bioceramic scaffolds in the repair of bone defects.

Physical, mechanical, and biological characterization of robocasted carbon nanotube reinforced microwave sintered calcium phosphate scaffolds for bone tissue engineering

This study analyses the influence of the addition of Multi Walled Carbon Nanotubes (MWCNT) on the physical, mechanical, and biological behaviour of Calcium Phosphate (CP) bone scaffolds developed using the robocasting technique for bone regeneration. Three different mass percentages (0.5, 1, and 2 wt%) of MWCNT are added to the CP powder and a slurry is prepared using a CMC binder for printing the scaffolds. The scaffolds were printed in 2 infill ratios, 50 and 100%, and were sintered under an inert atmosphere in a microwave furnace which was then taken for various characterization studies. Physical characterisation studies revealed that the shrinkage rate of scaffolds is very low compared to other additive manufacturing techniques. The incorporation of 0.5 wt% of MWCNT produced the best results in mechanical characterization studies with a compressive strength of 10.38 MPa and 11.89 MPa for 50% and 100% infill ratios respectively. In Vitro Biocompatibility studies also proved that 0.5 wt% MWCNT samples are the most suitable for cell growth while the hemocompatibility tests showed that the samples are blood compatible. . The 100% infill samples fared better than the 50% samples in physical and mechanical properties. The results suggest that the MWCNT incorporated CP scaffolds can be used to treat critical size bone defects.

Rationally-designed self-shaped ceramics through heterogeneous green body compositions

Forming ceramics into rationally-designed and complex shapes without compromising their mechanical properties is a major challenge. Here, we demonstrate self-shaping of ceramics through sequential stereolithographic printing of ceramic resins into components with a heterogeneous concentration of ceramic particles, resulting in well-defined anisotropic shrinkage and, consequently, shape changes during sintering. The method is versatile and scalable and results in well-controlled shape changes in ceramics through bending, folding, twisting, and combinations of these mechanisms. The density measurements and mechanical tests show that the stresses resulting from the self-shaping mechanisms do not significantly affect the physical and mechanical properties of the ceramics. Together with the experiments, we developed a material- and scale-independent mechanical model based on linear elasticity that predicted shape changes accurately. The model can serve as a design tool to guide the selection of particle concentrations to realize the desired shapes in a broad range of ceramics.

Robocasting and Laser Micromachining of Sol-Gel Derived 3D Silica/Gelatin/β-TCP Scaffolds for Bone Tissue Regeneration

The design and synthesis of sol-gel silica-based hybrid materials and composites offer significant benefits to obtain innovative biomaterials with controlled porosity at the nanostructure level for applications in bone tissue engineering. In this work, the combination of robocasting with sol-gel ink of suitable viscosity prepared by mixing tetraethoxysilane (TEOS), gelatin and β-tricalcium phosphate (β-TCP) allowed for the manufacture of 3D scaffolds consisting of a 3D square mesh of interpenetrating rods, with macropore size of 354.0 ± 17.0 μm, without the use of chemical additives at room temperature. The silica/gelatin/β-TCP system underwent irreversible gelation, and the resulting gels were also used to fabricate different 3D structures by means of an alternative scaffolding method, involving high-resolution laser micromachining by laser ablation. By this way, 3D scaffolds made of 2 mm thick rectangular prisms presenting a parallel macropore system drilled through the whole thickness and consisting of laser micromachined holes of 350.8 ± 16.6-micrometer diameter, whose centers were spaced 1312.0 ± 23.0 μm, were created. Both sol-gel based 3D scaffold configurations combined compressive strength in the range of 2–3 MPa and the biocompatibility of the hybrid material. In addition, the observed Si, Ca and P biodegradation provided a suitable microenvironment with significant focal adhesion development, maturation and also enhanced in vitro cell growth. In conclusion, this work successfully confirmed the feasibility of both strategies for the fabrication of new sol-gel-based hybrid scaffolds with osteoconductive properties.

Matrix-Directed Mineralization for Bulk Structural Materials

Mineral-based bulk structural materials (MBSMs) are known for their long history and extensive range of usage. The inherent brittleness of minerals poses a major problem to the performance of MBSMs. To overcome this problem, design principles have been extracted from natural biominerals, in which the extraordinary mechanical performance is achieved via the hierarchical organization of minerals and organics. Nevertheless, precise and efficient fabrication of MBSMs with bioinspired hierarchical structures under mild conditions has long been a big challenge. This Perspective provides a panoramic view of an emerging fabrication strategy, matrix-directed mineralization, which imitates the in vivo growth of some biominerals. The advantages of the strategy are revealed by comparatively analyzing the conventional fabrication techniques of artificial hierarchically structured MBSMs and the biomineral growth processes. By introducing recent advances, we demonstrate that this strategy can be used to fabricate artificial MBSMs with hierarchical structures. Particular attention is paid to the mass transport and the precursors that are involved in the mineralization process. We hope this Perspective can provide some inspiring viewpoints on the importance of biomimetic mineralization in material fabrication and thereby spur the biomimetic fabrication of high-performance MBSMs.

Robocasting of advanced ceramics: ink optimization and protocol to predict the printing parameters - A review

Direct-Ink-Writing (or robocasting) is a subset of extrusion-based additive manufacturing techniques that has grown significantly in recent years to design simple to complex ceramic structures. Robocasting, relies on the use of high-concentration powder pastes, also known as inks. A successful optimization of ink rheology and formulation constitutes the major key factor to ensure printability for the fabrication of self-supporting ceramic structures with a very precise dimensional resolution. However, to date achieving a real balance between a comprehensive optimization of ink rheology and the determination of a relevant protocol to predict the printing parameters for a given ink is still relatively scarce and has been not yet standardized in the literature. The current review reports, in its first part, a detailed survey of recent studies on how ink constituents and composition affect the direct-ink-writing of ceramic parts, taking into account innovative ceramic-based-inks formulations and processing techniques. Precisely, the review elaborates the major factors influencing on ink rheology and printability, specifically binder type, particle physical features (size, morphology and density) and ceramic feedstock content. In the second part, this review suggests a standardized guideline to effectively adapt a suitable setting of the printing parameters, such as printing speed and pressure, printing substrate, strut spacing, layer height, nozzle diameter in function of ink intrinsic rheology.

3D printed zirconia dental implants with integrated directional surface pores combine mechanical strength with favorable osteoblast response

Dental implants need to combine mechanical strength with promoted osseointegration. Currently used subtractive manufacturing techniques require a multi-step process to obtain a rough surface topography that stimulates osseointegration. Advantageously, additive manufacturing (AM) enables direct implant shaping with unique geometries and surface topographies. In this study, zirconia implants with integrated lamellar surface topography were additively manufactured by nano-particle ink-jetting. The ISO-14801 fracture load of as-sintered implants (516±39 N) resisted fatigue in 5-55°C water thermo-cycling (631±134 N). Remarkably, simultaneous mechanical fatigue and hydrothermal aging at 90°C significantly increased the implant strength to 909±280 N due to compressive stress generated at the seamless transition of the 30-40 µm thick, rough and porous surface layer to the dense implant core. This unique surface structure induced an elongated osteoblast morphology with uniform cell orientation and allowed for osteoblast proliferation, long-term attachment and matrix mineralization. In conclusion, the developed AM zirconia implants not only provided high long-term mechanical resistance thanks to the dense core along with compressive stress induced at the transition zone, but also generated a favorable osteoblast response owing to the integrated directional surface pores. STATEMENT OF SIGNIFICANCE: : Zirconia ceramics are becoming the material of choice for metal-free dental implants, however significant efforts are required to obtain a rough/porous surface for enhanced osseointegration, along with the risk of surface delamination and/or microstructure variation. In this study, we addressed the challenge by additively manufacturing implants that seamlessly combine dense core with a porous surface layer. For the first time, a unique surface with a directional lamellar pore morphology was additively obtained. This AM implant also provided strength as strong as conventionally manufactured zirconia implants before and after long-term fatigue. Favorable osteoblast response was proved by in-vitro cell investigation. This work demonstrated the opportunity to AM fabricate novel ceramic implants that can simultaneously meet the mechanical and biological functionality requirements.

Hierarchical Porous Ceramics with Distinctive Microstructures by Emulsion-Based Direct Ink Writing

Hierarchical porous materials are ubiquitous in nature and have inspired the fabrication of cellular structures for a multitude of applications. As an extrusion-based 3D printing technique, direct ink writing (DIW) allows for customizable design and accurate control of printed structures. Recently, its combination with colloidal processing methods used for bulk porous ceramics, such as emulsion templating, has further extended its capability of fabricating porous ceramics across multiple length scales. In light of the recent development, the ink formulation for emulsion-based DIW can be further explored, and there is still a need for a better understanding of the structure-property relationship. Herein, we introduce two types of gelling additives, i.e., poly(ethylenimine) (PEI) and Pluronic F-127, respectively, into particle-stabilized emulsions and fabricate hierarchical porous alumina lattices by DIW. We discover that the two gelling additives can lead to distinctive microstructures due to their different gelling mechanisms. Moreover, the 3D printed hierarchical porous ceramic lattices are found to exhibit a potential energy absorption property. The effects of ink formulations, including gelling additives and solid loading, on ink rheology, microstructure, and mechanical properties are investigated. The 3D printed hierarchical porous ceramic lattices exhibit a high average porosity of 73.7%-79.3% with an average compressive strength of 1.53-9.61 MPa and a specific energy absorption of 0.33-2.67 J/g. Featuring two distinctive microstructures with tunable structural features and mechanical properties, the 3D printed hierarchical porous ceramics in this study have potential in many applications, including lightweight structures, tissue engineering scaffolds, filtration, etc.

Tailorable Nanoporous Hydroxyapatite Scaffolds for Electrothermal Catalysis

Polarized hydroxyapatite (HAp) scaffolds with customized architecture at the nanoscale have been presented as a green alternative to conventional catalysts used for carbon and dinitrogen fixation. HAp printable inks with controlled nanoporosity and rheological properties have been successfully achieved by incorporating Pluronic hydrogel. Nanoporous scaffolds with good mechanical properties, as demonstrated by means of the nanoindentation technique, have been obtained by a sintering treatment and the posterior thermally induced polarization process. Their catalytic activity has been evaluated by considering three different key reactions (all in the presence of liquid water): (1) the synthesis of amino acids from gas mixtures of N₂, CO₂, and CH₄; (2) the production of ethanol from gas mixtures of CO₂ and CH₄; and (3) the synthesis of ammonia from N₂ gas. Comparison of the yields obtained by using nanoporous and nonporous (conventional) polarized HAp catalysts shows that both the nanoporosity and water absorption capacity of the former represent a drawback when the catalytic reaction requires auxiliary coating layers, as for example for the production of amino acids. This is because the surface nanopores achieved by incorporating Pluronic hydrogel are completely hindered by such auxiliary coating layers. On the contrary, the catalytic activity improves drastically for reactions in which the HAp-based scaffolds with enhanced nanoporosity are used as catalysts. More specifically, the carbon fixation from CO₂ and CH₄ to yield ethanol improves by more than 3000% when compared with nonporous HAp catalyst. Similarly, the synthesis of ammonia by dinitrogen fixation increases by more than 2000%. Therefore, HAp catalysts based on nanoporous scaffolds exhibit an extraordinary potential for scalability and industrial utilization for many chemical reactions, enabling a feasible green chemistry alternative to catalysts based on heavy metals.

3D Printing of Metal-Organic Framework-Based Ionogels: Wearable Sensors with Colorimetric and Mechanical Responses

Soft ionotronics are emerging materials as wearable sensors for monitoring physiological signals, sensing environmental hazards, and bridging the human-machine interface. However, the next generation of wearable sensors requires multiple sensing capabilities, mechanical toughness, and 3D printability. In this study, a metal-organic framework (MOF) and three-dimensional (3D) printing were integrated for the synthesis of a tough MOF-based ionogel (MIG) for colorimetric and mechanical sensing. The ink for 3D printing contained deep eutectic solvents (DESs), cellulose nanocrystals (CNCs), MOF crystals, and acrylamide. After printing, further photopolymerization resulted in a second covalently cross-linked poly(acrylamide) network and solidification of MIG. As a porphyrinic Zr-based MOF, MOF-525 served as a functional filler to provide sharp color changes when exposed to acidic compounds. Notably, MOF-525 crystals also provided another design space to tune the printability and mechanical strength of MIG. In addition, the printed MIG exhibited high stability in the air because of the low volatility of DESs. Thereafter, wearable auxetic materials comprising MIG with negative Poisson's ratios were prepared by 3D printing for the detection of mechanical deformation. The resulting auxetic sensor exhibited high sensitivity via the change in resistance upon mechanical deformation and a conformal contact with skins to monitor various human body movements. These results demonstrate a facile strategy for the construction of multifunctional sensors and the shaping of MOF-based composite materials.

Experimental Quantification of Gas Dispersion in 3D-Printed Logpile Structures Using a Noninvasive Infrared Transmission Technique

3D-printed catalyst structures have the potential to broaden reactor operating windows. However, the hydrodynamic aspects associated with these novel catalyst structures have not yet been quantified in detail. This work applies a recently introduced noninvasive, instantaneous, whole-field concentration measurement technique based on infrared transmission to quantify the rate of transverse gas dispersion in 3D-printed logpile structures. Twenty-two structural variations have been investigated at various operating conditions, and the measured transverse gas dispersion has been correlated to the Péclet number and the structures’ porosity and feature size. It is shown that staggered configurations of these logpile structures offer significantly more tunability of the dispersion behavior compared to straight structures. The proposed correlations can be used to facilitate considerations of reactor design and operating windows.

Compressive properties and failure behavior of photocast hydroxyapatite gyroid scaffolds vary with porosity

Hydroxyapatite is commonly used in tissue engineered scaffolds for bone regeneration due to its excellent bioactivity and slow degradation rate in the human body. A method of layer-wise, photopolymerized viscous extrusion, a type of additive manufacturing, was developed to fabricate hydroxyapatite gyroid scaffolds with 60%, 70%, and 80% porosities. This study uses this method to produce and evaluate calcium phosphate-based scaffolds. Gyroid topology was selected due to its interconnected porosity and superior, isotropic mechanical properties compared to typical rectilinear lattice structures. These 3D printed scaffolds were mechanically tested in compression and examined to determine the relationship between porosity, ultimate compressive strength, and fracture behavior. Compressive strength increased with decreasing porosity. Ultimate compressive strengths of the 60% and 70% porous gyroids are comparable to that of human cancellous bone, and higher than previously reported for hydroxyapatite rectilinear scaffolds. These gyroid scaffolds exhibited ultimate compressive strength increases between 1.5 and 6.5 times greater than expected, based on volume of material, as porosity is decreased. The Weibull moduli, a measure of failure predictability, were predictive of failure mode and found to be in the accepted range for engineering ceramics. The gyroid scaffolds were also found to be self-reinforcing such that initial failures due to minor manufacturing inconsistencies did not appear to be the primary cause of early failure of the scaffold. The porous gyroids exhibited scaffold failure characteristics that varied with porosity, ranging from monolithic failure to layer-by-layer failure, and demonstrated self-reinforcement in each porosity tested.

Review on Additive Manufacturing of Catalysts and Sorbents and the Potential for Process Intensification

Additive manufacturing of catalyst and sorbent materials promises to unlock large design freedom in the structuring of these materials, and could be used to locally tune porosity, shape and resulting parameters throughout the reactor along both the axial and transverse coordinates. This contrasts catalyst structuring by conventional methods, which yields either very dense randomly packed beds or very open cellular structures. Different 3D-printing processes for catalytic and sorbent materials exist, and the selection of an appropriate process, taking into account compatible materials, porosity and resolution, may indeed enable unbounded options for geometries. In this review, recent efforts in the field of 3D-printing of catalyst and sorbent materials are discussed. It will be argued that these efforts, whilst promising, do not yet exploit the full potential of the technology, since most studies considered small structures that are very similar to structures that can be produced through conventional methods. In addition, these studies are mostly motivated by chemical and material considerations within the printing process, without explicitly striving for process intensification. To enable value-added application of 3D-printing in the chemical process industries, three crucial requirements for increased process intensification potential will be set out: i) the production of mechanically stable structures without binders; ii) the introduction of local variations throughout the structure; and iii) the use of multiple materials within one printed structure.

Colloidal oxide nanoparticle inks for micrometer-resolution additive manufacturing of three-dimensional gas sensors

Micrometer-resolution 3D printing of functional oxides is of growing importance for the fabrication of micro-electromechanical systems (MEMSs) with customized 3D geometries. Compared to conventional microfabrication methods, additive manufacturing presents new opportunities for the low-cost, energy-saving, high-precision, and rapid manufacturing of electronics with complex 3D architectures. Despite these promises, methods for printable oxide inks are often hampered by challenges in achieving the printing resolution required by today's MEMS electronics and integration capabilities with various other electronic components. Here, a novel, facile ink design strategy is presented to overcome these challenges. Specifically, we first prepare a high-solid loading (∼78 wt%) colloidal suspension that contains polyethyleneimine (PEI)-coated stannic dioxide (SnO₂) nanoparticles, followed by PEI desorption that is induced by nitric acid (HNO₃) titration to optimize the rheological properties of the printable inks. Our achieved ∼3-5 μm printing resolution is at least an order of magnitude higher than those of other printed oxide studies employing nanoparticle ink-based printing methods demonstrated previously. Finally, various SnO₂ structures were directly printed on a MEMS-based microelectrode for acetylene detection application. The gas sensitivity measurements reveal that the device performance is strongly dependent on the printed SnO₂ structures. Specifically, the 3D structured SnO₂ gas sensor exhibits the highest response of ∼ 29.9 to 100 ppm acetylene with the fastest total response time of ∼ 65.8 s. This work presents a general ink formulation and printing strategy for functional oxides, which further provides a pathway for the additive manufacturing of oxide-based MEMSs.

Integrating pore architectures to evaluate vascularization efficacy in silicate-based bioceramic scaffolds

Pore architecture in bioceramic scaffolds plays an important role in facilitating vascularization efficiency during bone repair or orbital reconstruction. Many investigations have explored this relationship but lack integrating pore architectural features in a scaffold, hindering optimization of architectural parameters (geometry, size and curvature) to improve vascularization and consequently clinical outcomes. To address this challenge, we have developed an integrating design strategy to fabricate different pore architectures (cube, gyroid and hexagon) with different pore dimensions (∼350, 500 and 650 μm) in the silicate-based bioceramic scaffolds via digital light processing technique. The sintered scaffolds maintained high-fidelity pore architectures similar to the printing model. The hexagon- and gyroid-pore scaffolds exhibited the highest and lowest compressive strength (from 15 to 55 MPa), respectively, but the cube-pore scaffolds showed appreciable elastic modulus. Moreover, the gyroid-pore architecture contributed on a faster ion dissolution and mass decay in vitro. It is interesting that both μCT and histological analyses indicate vascularization efficiency was challenged even in the 650-μm pore region of hexagon-pore scaffolds within 2 weeks in rabbit models, but the gyroid-pore constructs indicated appreciable blood vessel networks even in the 350-μm pore region at 2 weeks and high-density blood vessels were uniformly invaded in the 500- and 650-μm pore at 4 weeks. Angiogenesis was facilitated in the cube-pore scaffolds in comparison with the hexagon-pore ones within 4 weeks. These studies demonstrate that the continuous pore wall curvature feature in gyroid-pore architecture is an important implication for biodegradation, vascular cell migration and vessel ingrowth in porous bioceramic scaffolds.

Flexural strength of 3Y-TZP bioceramics obtained by direct write assembly as function of residual connected-porosity

OBJECTIVES

The present work reports the effect of the extrusion nozzles' size and consequent residual porosity on the flexural strength of 3Y-TZP bioceramics fabricated by direct write assembly technology.

METHODS

A printable ink containing a volume fraction of 45% of 3Y-TZP (ZrO₂ stabilized with 3 mol% Y₂O₃) submicron powder, carboxymethyl cellulose and polyethyleneimine as additives was fine-tuned by rheological measurements. Different nozzle diameters (0.41 mm, 0.33 mm, and 0.25 mm) were used to print 3D specimens with proper dimensions for structural and mechanical characterization after sintering, namely relative density, linear shrinkage, and three-point flexural strength. Bulk surface sample and exposed fractured surfaces after flexural strength tests were analyzed by X-ray diffraction, Rietveld refinement and scanning electronic microscopy. Strength reliability and failure probability of the three sample groups were analyzed by Weibull statistics.

RESULTS

The sintered samples exhibited relative densities in the range of 78% (nozzle Ø 0.41 = mm) and 82% (nozzle Ø 0.25 = mm), i.e., a slight increase in the residual interfilamentous porosity is observed, as the extrusion tip diameter increases, while linear shrinkage is statistically similar (≈25%). Likewise, a progressive reduction of flexural strength and Weibull modulus as nozzle diameter increases was noticeable, being respectively σ_f = 337,5 ± 49 MPa and m = 6.6 for the smallest nozzle diameter (Ø = 0.25 mm) and σ_f = 261.4 ± 79 MPa and m = 3.2 for the biggest one (Ø = 0.41 mm). Unlike nozzle diameter, the material is constituted by 79-81 wt% tetragonal t-ZrO₂ and 19-21 wt% cubic c-ZrO₂ with equiaxed grain sizes between 0.3 and 0.6 μm.

CONCLUSION

X-ray diffraction analyses on the fracture surface of flexural test samples suggests that the toughening mechanism by tetragonal→ monoclinic phase transformation is the main responsible for the mechanical strength of this structural ceramic. Additionally, the reduction of flexural strength for samples printed with extrusion nozzle of 0.41 mm could be explained by the surface roughness of the bending surfaces, as well as the lower effective resistance to crack-propagation arising from the higher size of residual pores on the fracture surface.

Applying extrusion-based 3D printing technique accelerates fabricating complex biphasic calcium phosphate-based scaffolds for bone tissue regeneration

•

Biphasic calcium phosphates offer a chemically similar biomaterial to the natural bone, which can significantly accelerate bone formation and reconstruction.

•

Robocasting is a suitable technique to produce porous scaffolds supporting cell viability, proliferation, and differentiation.

•

This review discusses materials and methods utilized for BCP robocasting, considering recent advancements and existing challenges in using additives for bioink preparation.

•

Commercialization and marketing approach, in-vitro and in-vivo evaluations, biologic responses, and post-processing steps are also investigated.

•

Possible strategies and opportunities for the use of BCP toward injured bone regeneration along with clinical applications are discussed.

•

The study proposes that BCP possesses an acceptable level of bone substituting, considering its challenges and struggles.

Background

Aim of review

Key scientific concepts of review

Toward stronger robocast calcium phosphate scaffolds for bone tissue engineering: A mini-review and meta-analysis

Among different treatments of critical-sized bone defects, bone tissue engineering (BTE) is a fast-developing strategy centering around the fabrication of scaffolds that can stimulate tissue regeneration and provide mechanical support at the same time. This area has seen an extensive application of bioceramics, such as calcium phosphate, for their bioactivity and resemblance to the composition of natural bones. Moreover, recent advances in additive manufacturing (AM) have unleashed enormous potential in the fabrication of BTE scaffolds with tailored porous structures as well as desired biological and mechanical properties. Robocasting is an AM technique that has been widely applied to fabricate calcium phosphate scaffolds, but most of these scaffolds do not meet the mechanical requirements for load-bearing BTE scaffolds. In light of this challenge, various approaches have been utilized to mechanically strengthen the scaffolds. In this review, the current state of knowledge and existing research on robocasting of calcium phosphate scaffolds are presented. Applying the Gibson-Ashby model, this review provides a meta-analysis from the published literature of the compressive strength of robocast calcium phosphate scaffolds. Furthermore, this review evaluates different approaches to the mechanical strengthening of robocast calcium phosphate scaffolds. The aim of this review is to provide insightful data and analysis for future research on mechanical strengthening of robocast calcium phosphate scaffolds and ultimately for their clinical applications.

Additive Manufacturing of Micro-Electro-Mechanical Systems (MEMS)

Recently, additive manufacturing (AM) processes applied to the micrometer range are subjected to intense development motivated by the influence of the consolidated methods for the macroscale and by the attraction for digital design and freeform fabrication. The integration of AM with the other steps of conventional micro-electro-mechanical systems (MEMS) fabrication processes is still in progress and, furthermore, the development of dedicated design methods for this field is under development. The large variety of AM processes and materials is leading to an abundance of documentation about process attempts, setup details, and case studies. However, the fast and multi-technological development of AM methods for microstructures will require organized analysis of the specific and comparative advantages, constraints, and limitations of the processes. The goal of this paper is to provide an up-to-date overall view on the AM processes at the microscale and also to organize and disambiguate the related performances, capabilities, and resolutions.

3D Printing of Thermal Insulating Polyimide/Cellulose Nanocrystal Composite Aerogels with Low Dimensional Shrinkage

Polyimide (PI)-based aerogels have been widely applied to aviation, automobiles, and thermal insulation because of their high porosity, low density, and excellent thermal insulating ability. However, the fabrication of PI aerogels is still restricted to the traditional molding process, and it is often challenging to prepare high-performance PI aerogels with complex 3D structures. Interestingly, renewable nanomaterials such as cellulose nanocrystals (CNCs) may provide a unique approach for 3D printing, mechanical reinforcement, and shape fidelity of the PI aerogels. Herein, we proposed a facile water-based 3D printable ink with sustainable nanofillers, cellulose nanocrystals (CNCs). Polyamic acid was first mixed with triethylamine to form an aqueous solution of polyamic acid ammonium salts (PAAS). CNCs were then dispersed in the aqueous PAAS solution to form a reversible physical network for direct ink writing (DIW). Further freeze-drying and thermal imidization produced porous PI/CNC composite aerogels with increased mechanical strength. The concentration of CNCs needed for DIW was reduced in the presence of PAAS, potentially because of the depletion effect of the polymer solution. Further analysis suggested that the physical network of CNCs lowered the shrinkage of aerogels during preparation and improved the shape-fidelity of the PI/CNC composite aerogels. In addition, the composite aerogels retained low thermal conductivity and may be used as heat management materials. Overall, our approach successfully utilized CNCs as rheological modifiers and reinforcement to 3D print strong PI/CNC composite aerogels for advanced thermal regulation.

A gravity-driven sintering method to fabricate geometrically complex compact piezoceramics

Highly compact and geometrically complex piezoceramics are required by a variety of electromechanical devices owing to their outstanding piezoelectricity, mechanical stability and extended application scenarios. 3D printing is currently the mainstream technology for fabricating geometrically complex piezoceramic components. However, it is hard to print piezoceramics in a curve shape while also keeping its compactness due to restrictions on the ceramic loading and the viscosity of feedstocks. Here, we report a gravity-driven sintering (GDS) process to directly fabricate curved and compact piezoceramics by exploiting gravitational force and high-temperature viscous behavior of sintering ceramic specimens. The sintered lead zirconate titanate (PZT) ceramics possess curve geometries that can be facilely tuned via the initial mechanical boundary design, and exhibit high piezoelectric properties comparable to those of conventional-sintered compact PZT (d33 = 595 pC/N). In contrast to 3D printing technology, our GDS process is suitable for scale-up production and low-cost production of piezoceramics with diverse curved surfaces. Our GDS strategy is an universal and facile route to fabricate curved piezoceramics and other functional ceramics with no compromise of their functionalities.

Construction of the Gypsum-Coated Scaffolds for In Situ Bone Regeneration

It is significant to use functional biomaterials to rationally engineer microenvironments for in situ bone regeneration in the field of bone tissue engineering. To this end, we constructed the gypsum-coated β-tricalcium phosphate (G-TCP) scaffolds by combing a three-dimensional printing technique and an epitaxial gypsum growth method. In vitro simulation experiments showed that the as-prepared scaffolds could establish a dynamic and weakly acidic microenvironment in a simulated body liquid, in which the pH and the calcium ion concentration always changed due to the gypsum degradation and growth of bone-like apatite nanoplates on the scaffold surfaces. The cell experiments confirmed that the microenvironment established by the G-TCP surfaces promoted rapid osteogenic differentiation and proliferation of bone marrow mesenchymal stem cells (BM-MSCs). In vivo experiments confirmed that the G-TCP scaffolds had high bioactivity in modulating in situ regeneration of bone, and the bioactivity of the G-TCP scaffolds was endowed by correct pore structures, degradation of gypsum, and growth of a bone-like apatite layer. The microenvironment established by the gypsum degradation could stimulate tissue inflammation and recruit white blood cells and BM-MSCs and thus accelerating native healing cascades of the bone defects via a bone growth/remodeling-absorption cycle process. Furthermore, in vivo experiments demonstrated that after the bone defects had healed completely, the as-prepared scaffolds also degraded completely within 24 weeks.

Long-term stabilized amorphous calcium carbonate-an ink for bio-inspired 3D printing

Biominerals formed by organisms in the course of biomineralization often demonstrate complex morphologies despite their single-crystalline nature. This is achieved owing to the crystallization via a predeposited amorphous calcium carbonate (ACC) phase, a precursor that is particularly widespread in biominerals. Inspired by this natural strategy, we used robocasting, an additive manufacturing three-dimensional (3D) printing technique, for printing 3D objects from novel long-term, Mg-stabilized ACC pastes with high solids loading. We demonstrated, for the first time, that the ACC remains stable for at least a couple of months, even after printing. Crystallization, if desired, occurs only after the 3D object is already formed and at temperatures significantly lower than those of common postprinting sintering. We also examined the effects different organic binders have on the crystallization, the morphology, and the final amount of incorporated Mg. This novel bio-inspired method may pave the way for a new bio-inspired route to low-temperature 3D printing of ceramic materials for a multitude of applications.

3D Printing of Transparent Spinel Ceramics with Transmittance Approaching the Theoretical Limit

3D printing of transparent ceramics has attracted great attention recently but faces the challenges of low transparency and low printing resolution. Herein, magnesium aluminate spinel transparent ceramics with transmittance reaching 97% of the theoretical limit are successfully fabricated using a stereolithography-based 3D printing method assisted by hot isostatic pressing and the critical factors governing the transparency are revealed. Various transparent spinel lenses and microlattices are printed at a high resolution of ≈100-200 µm. The 3D printed spinel lens demonstrates fairly good optical imaging ability, and the printed spinel diamond microlattices as a transparent photocatalyst support for TiO₂ significantly enhance its photocatalytic efficiency compared with its opaque counterparts. Compared with other 3D printed transparent materials such as silica glass or organic polymers, the printed spinel ceramics have the advantages of broad optical window, high hardness, excellent high-temperature stability, and chemical resistance and therefore, have great potential to be used in various optical lenses/windows and photocatalyst supports for application in harsh environments.

Cationic Cellulose Nanocrystals-Based Nanocomposite Hydrogels: Achieving 3D Printable Capacitive Sensors with High Transparency and Mechanical Strength

Hydrogel ionotronics are intriguing soft materials that have been applied in wearable electronics and artificial muscles. These applications often require the hydrogels to be tough, transparent, and 3D printable. Renewable materials like cellulose nanocrystals (CNCs) with tunable surface chemistry provide a means to prepare tough nanocomposite hydrogels. Here, we designed ink for 3D printable sensors with cationic cellulose nanocrystals (CCNCs) and zwitterionic hydrogels. CCNCs were first dispersed in an aqueous solution of monomers to prepare the ink with a reversible physical network. Subsequent photopolymerization and the introduction of Al3+ ion led to strong hydrogels with multiple physical cross-links. When compared to the hydrogels using conventional CNCs, CCNCs formed a stronger physical network in water that greatly reduced the concentration of nanocrystals needed for reinforcing and 3D printing. In addition, the low concentration of nanofillers enhanced the transparency of the hydrogels for wearable electronics. We then assembled the CCNC-reinforced nanocomposite hydrogels with stretchable dielectrics into capacitive sensors for the monitoring of various human activities. 3D printing further enabled a facile design of tactile sensors with enhanced sensitivity. By harnessing the surface chemistry of the nanocrystals, our nanocomposite hydrogels simultaneously achieved good mechanical strength, high transparency, and 3D printability.

3D Printable Strain Sensors from Deep Eutectic Solvents and Cellulose Nanocrystals

Stretchable and conductive hydrogels have been intensively studied as wearable electronics to monitor the physiological activities of human bodies. However, it remains a challenge to fabricate robust hydrogels as sensors with complex 3D structures. Here, we designed a 3D printable ink from cellulose nanocrystals (CNCs), deep eutectic solvents (DESs), and ionically cross-linked polyacrylic acid (PAA). DESs composed of choline chloride and ethylene glycol served as a nonvolatile medium with high ionic conductivity. The dispersion of CNCs in a mixture of DESs, acrylic acid, and Al³⁺ ions formed ionogels with a reversible physical network for 3D printing. After the printing process, the ionogel was solidified by the photopolymerization of acrylic acid in the presence of Al³⁺ ions to form a second ionically cross-linked network. The first physical network of CNCs provides an energy-dissipating mechanism to make a strong and highly stretchable nanocomposite ionogel. When compared to hydrogels, we found that the DES/CNC nanocomposite ionogel was more stable in the air because of the low volatility of DESs. We further used the DES/CNC ink to 3D print an auxetic sensor with negative Poisson's ratios so that the sensor provided a conformal contact with the skin during large deformation. In addition, the auxetic sensor could continuously monitor and identify different motions of the human body by the change in resistance. These results demonstrate a simple and rapid strategy to fabricate stable and sensitive strain sensors from cheap and renewable feedstock.