Abstract The macro-porous ceramics has promising durability and thermal insulation performance. As porous ceramics find more and more applications across many industries, a cost-effective and scalable additive manufacturing technique for fabricating macro-porous ceramics is highly desirable. Herein, we reported a facile additive manufacturing approach to fabricate porous ceramics and control the printed porosity. Several printable ceramic inks were prepared, and the foaming agent was added to generate gaseous bubbles in the ink, followed by the direct ink writing and the ambient-pressure and room-temperature drying to create the three-dimensional geometries. A set of experimental studies were performed to optimize the printing quality. The results revealed the optimal process parameters for printing the foamed ceramic ink with a high spatial resolution and fine surface quality. Varying the concentration of the foaming agent enables the controllability of the structural porosity. The maximum porosity can reach 85%, with a crack-free internal porous structure. The tensile tests showed that the printed macro-porous ceramics possessed enhanced durability with the addition of fiber. With a high-fidelity three-dimensional (3D) printing process and the precise controllability of the porosity, we showed that the printed samples exhibited a remarkably low thermal conductivity and durable mechanical strength.
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Bone-inspired healing of 3D-printed porous ceramics
Emerging 3D-printed ceramics, though showing unprecedented application potential, are typically vulnerable to fractures and unable to heal at room temperature. By contrast, their natural counterparts, human bones, exhibit extraordinary self-healing capability through the activation of stem cell osteoblasts that precipitate mineralized calluses to enable interfacial healing at body temperature. Inspired by bones, we here employ bacteria as artificial osteoblasts to enable healing of 3D-printed porous ceramics at room temperature. The healing behavior relies on bacteria-initiated precipitation of calcium carbonate crystals to bridge fracture interfaces of ceramics. We show that bacteria-loaded porous ceramics can heal fracture interfaces to restore 100% mechanical strength at room temperature, and the healed strength is not compromised by heating up to 500 C or by corrosion of alkalis and oxidants. The bacteria-assisted healing mechanism is revealed by systematic control experiments, and the healing strength is explained by cohesive fracture modeling. We further incorporate this method into 3D-printed ceramics and demonstrate on-demand healing of ceramic dental crowns, ceramic water membranes, and ceramic lattices, and autonomous healing of ceramic armor. As the first-generation healing mechanism of 3D-printed ceramics, this paradigm is expected to open promising avenues for revolutionizing the low-damage-tolerance nature of existing 3D-printed ceramics.
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- Award ID(s):
- 1762567
- NSF-PAR ID:
- 10179399
- Date Published:
- Journal Name:
- Materials Horizons
- ISSN:
- 2051-6347
- Format(s):
- Medium: X
- Sponsoring Org:
- National Science Foundation
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Abstract The macro-porous ceramics has promising durability and thermal insulation performances. A cost-effective and scalable additive manufacturing technique for the fabrication of macro-porous ceramics, with a facile approach to control the printed porosity is reported in the paper. Several ceramic inks were prepared, the foaming agent was used to generate gaseous bubbles in the ink, followed by the direct ink writing and the ambient-pressure and room-temperature drying to create the three-dimensional geometries. The experimental studies were performed to optimize the printing quality. A set of studies revealed the optimal printing process parameters for printing the foamed ceramic ink with a high spatial resolution and fine surface quality. Varying the concentration of the foaming agent enabled the controllability of the structural porosity. The maximum porosity can reach 85%, with a crack-free internal porous structure. The tensile tests showed that the printed macro-porous ceramics have enhanced durability with the addition of fiber. With a high-fidelity 3D printing process and precise control of the porosity, the printed samples exhibited a low thermal conductivity and high mechanical strength.
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Ceramic materials provide outstanding chemical and structural stability at high temperatures and in hostile environments but are susceptible to catastrophic fracture that severely limits their applicability. Traditional approaches to partially overcome this limitation rely on activating toughening mechanisms during crack growth to postpone fracture. Here, we demonstrate a more potent toughening mechanism that involves an intriguing possibility of healing the cracks as they form, even at room temperature, in an atomically layered ternary carbide. Crystals of this class of ceramic materials readily fracture along weakly bonded crystallographic planes. However, the onset of an abstruse mode of deformation, referred to as kinking in these materials, induces large crystallographic rotations and plastic deformation that physically heal the cracks. This implies that the toughness of numerous other layered ceramic materials, whose broader applications have been limited by their susceptibility to catastrophic fracture, can also be enhanced by microstructural engineering to promote kinking and crack-healing.more » « less
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Human bone demonstrates superior mechanical properties due to its sophisticated hierarchical architecture spanning from the nano/microscopic level to the macroscopic. Bone grafts are in high demand due to the rising number of surgeries because of increasing incidence of orthopedic disorders, non‐union fractures, and injuries in the geriatric population. The bone scaffolds need to provide porous matrix with interconnected porosity for tissue growth as well as sufficient strength to withstand physiological loads, and be compatible with physiological remodeling by osteoclasts/osteoblasts. The‐state‐of‐art additive manufacturing (AM) technologies for bone tissue engineering enable the manipulation of gross geometries, for example, they rely on the gaps between printed materials to create interconnected pores in 3D scaffolds. Herein, the authors firstly print hierarchical and porous hydroxyapatite (HAP) structures with interconnected pores to mimic human bones from microscopic (below 10 µm) to macroscopic (submillimeter to millimeter level) by combining freeze casting and extrusion‐based 3D printing. The compression test of 3D printed scaffold demonstrates superior compressive stress (22 MPa) and strain (4.4%). The human mesenchymal stromal cells (MSCs) tests demonstrate the biocompatibility of printed scaffold.
- Free Publicly Accessible Full Text
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Accepted Manuscript1.0
- Journal Article:
- https://doi.org/10.1039/D0MH00131G
