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FAST-MED - Research project

Additive manufacturing by stereolithography of tough ceramics for medical application

ABSTRACT

Ceramic stereolithography is based on the scraping of an ink, followed by its selective polymerisation to form the printed part, layer by layer. The part is then debinded and sintered to obtain a dense ceramic object. Our work focuses on the fine characterisation of inks to control their response to mechanical and UV light involved at the different stages of the printing process, and to reduce the formation of defects. A detailed rheological study allowed to identify the effect of the different compounds on the structure of inks, affecting their response to scraping. We also propose an improved quantification of laser polymerisation in order to avoid printing inhomogeneous parts. In addition to reducing the occurrence of defects, we have printed composites based on ceria-doped zirconia of high mechanical reliability, a key factor for its application of this material in implantology.

 
PUBLICATIONS

CONFERENCES
  • S. Fournier, et al., Ceramic stereolithography paste rheology: structural evolution under shear and vibration fluidification effect, ECERS 2023 - Lyon - 2-6 July 2023
  • S. Fournier, et al., Multi-scale characterization of transformation-induced plasticity in Ceria-doped zirconia, ECERS 2023 - Lyon - 2-6 July 2023
  • S. Fournier, et al., Transformation-induced plasticity of zirconia-based ceramic composites: effect of the microstructure, Plasticité 2023 - Lyon - 3-5 Apr. 2023
  • S. Fournier, et al., A multi-physics approach to rationalize the properties of 3Y-TZP based stereolithography pastes, yCAM - Barcelona -  9-11 Nov. 2022
  • S. Fournier, et al., Additive manufacturing of ductile and tough zirconia-based ceramic composites, ESCI - Zurich - 20-22 Oct.2022
  • S. Fournier, et al., Increasing the reliability of bioceramics processed through stereolithography using tough zirconia-based composites, Bioceramics 32 - Venice Mestre - 20-23 Sept. 2022
  • S. Fournier, et al., Additive manufacturing by stereolithography of tough ceramics for medical applications: From the development of specific pastes to suitable compositions and architectures, 17th European Inter-Regional Conference on Ceramics, 2021 - http://ciec17.com/
  • Sylvain Fournier, Jérôme Chevalier, Saray Perez-Robles, Claudia Carotenuto, Mario Minale, Helen Reveron, Guilhem P Baeza, "On the Spreadability of Stereolithography Pastes for the Design of Strong Ceramic Parts : Steady shear and orthogonal rheology study", 5-7 June 2023, GDR SoPhy
  • Chevalier J, Fournier S, Baeza G, Maillard M, Gremillard L, Garnier V., "Achieving strong and tough 3D-printed ceramics: process optimisation and defect-tolerant materials", Bioceramics 33, Solothurn, Switzerland, October 2023