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. 2023 Jul 10;16(14):4924.
doi: 10.3390/ma16144924.

Energy-Reduced Fabrication of Light-Frame Ceramic Honeycombs by Replication of Additive Manufactured Templates

David Köllner  1 , Sebastian Niedermeyer  1 , Miklos Vermes  1 , Swantje Simon  1 , Ken-Ichi Kakimoto  2 , Tobias Fey  1   2
Affiliations

Energy-Reduced Fabrication of Light-Frame Ceramic Honeycombs by Replication of Additive Manufactured Templates

David Köllner et al. Materials (Basel). .

Abstract

Ceramic components require very high energy consumption due to synthesis, shaping, and thermal treatment. However, this study suggests that combining the sol-gel process, replica technology, and stereolithography has the potential to produce highly complex geometries with energy savings in each process step. We fabricated light-frame honeycombs of Al2O3, Ba0.85Ca0.15Zr0.1Ti0.9O3 (BCZT), and BaTiO3 (BT) using 3D-printed templates with varying structural angles between -30° and 30° and investigated their mechanical and piezoelectric properties. The Al2O3 honeycombs showed a maximum strength of approximately 6 MPa, while the BCZT and BaTiO3 honeycombs achieved a d33 above 180 pC/N. Additionally, the BCZT powder was prepared via a sol-gel process, and the impact of the calcination temperature on phase purity was analyzed. The results suggest that there is a large energy-saving potential for the synthesis of BCZT powder. Overall, this study provides valuable insights into the fabrication of complex ceramic structures with improved energy efficiency and enhancement of performance.

Keywords: additive manufacturing; ceramic honeycombs; piezoelectric porous ceramics; replica method; sol–gel method.

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Conflict of interest statement

The authors declare no conflict of interest.

Figures

Figure 1
Figure 1
Light-frame auxetic (θ < 0°) and hexagonal (θ ≥ 0°) unit cell with structural parameters Y: height, h: width, d: strut diameter, T: thickness, θ: angle.
Figure 2
Figure 2
Process scheme of the manufacturing of light frame honeycomb structures, by combining 3D-printing, replica technique and sol–gel powder synthesis.
Figure 3
Figure 3
(a): XRD analysis of the BCZT *(Ba0.85Ca0.15)(Zr0.1Ti0.9)O3 powder calcined between 600 °C and 800 °C for 5 h and related density determined via helium pycnometer. (b): TGA/DSC measurement of the BCZT xerogel for calcination with the different temperature reaction zones I–IV.
Figure 4
Figure 4
(a) Sintered light-frame ceramic honeycombs made of Al2O3, BCZT, and BaTiO3 with positive (hexagonal) and negative (auxetic) angles; (b) SEM image of a cross-sectional area of an Al2O3 strut with triangular pore; (c) 3D-printed polymer templates used in replication process (a); (d) Reference PU-Template and sintered BCZT replica foam from PU-Template.
Figure 5
Figure 5
(a) Porosity in dependence of the structural angle θ of Al2O3 light-frame honeycombs; (b) compressive strength of Al2O3 light-frame honeycombs as a function of the porosity with a fitted model from Phani et al. [43].
Figure 6
Figure 6
Piezoelectric properties of BT light-frame honeycombs and BCZT replica foams in dependence of the porosity; (a) piezoelectric charge coefficient d33; (b) relative permittivity with the fitted model from Okazaki.
See this image and copyright information in PMC

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