Porous structures printed by fused deposition of granules processed from a novel polyamide/alumina-based system

Abstract

Alumina ceramic porous structures were shaped by the fused deposition of alumina/polyamide 612 composite granules using an FDM 3D printer with a modified extruder to process granulated powder instead of a filament. The composite granules were prepared via thermally induced phase separation (TIPS). Firstly, in order to determine the proportion of polymer/solvent to be used in the TIPS process, different volume fractions of PA612 in dimethyl sulfoxide (DMSO) were studied (0.01 to 0.20), and the granules obtained were characterized by SEM, DSC, and Raman spectroscopy. Secondly, the addition of different ceramic loadings to the PA612/DMSO solution was studied with the aim of determining the amount to be used for preparing the composite granules by TIPS. In particular, the effect of the alumina content on the morphology and size of the obtained composite granules was studied. In addition, rheological properties (oscillatory and rotational tests) of the feed materials were studied. Finally, the printing conditions, including the nozzle temperature and nozzle diameter, and the extrusion process, were optimized in order to obtain porous structures with good quality. Alumina porous structures were successfully printed, debinded, and sintered. Adequate bonding between layers was achieved, and no defects at interfaces were detected.