Ink – Dev

CERAMIC PASTE for Direct Ink Writing (DIW)

Alex Kozlov — Sun, 25 Aug 2024 13:42:12 +0000

3D printing with ceramics is transforming various industries, capitalizing on ceramics’ renowned qualities such as exceptional heat resistance, mechanical strength, and electrical insulation. Notably, this technology is reshaping aerospace and automotive sectors by producing high-demand items like ceramic turbine blades and engine components, optimizing their performance and efficiency. These advancements in ceramic printing encompass a range of commonly procured items, including intricate ceramics and ceramic pastes. The techniques employed empower designers and engineers to enhance product performance, lower production costs, and explore innovative designs. This transformative technology is set to continue shaping industries and sparking creativity in modern ceramic-based manufacturing.

Ceramic Pastes Parameters:

• Aluminum Oxide (Al2O3): High thermal conductivity, electrical insulation, and resistance to wear and corrosion.

• Yttria-Stabilized Zirconia (YSZ): Excellent thermal and chemical stability, used in high-temperature applications.

• Silicon Carbide (SiC): Extremely hard and wear-resistant, with high thermal conductivity and chemical resistance.
• Zirconium Oxide (ZrO2): High fracture toughness and thermal expansion, suitable for structural applications.
• Aluminosilicate (Al2O3-SiO2): High-temperature stability and thermal shock resistance, used in refractory applications.
• Titanium Dioxide (TiO2): High refractive index and dielectric properties, commonly used in optical and electronic applications.

CERAMIC PASTES for Direct Ink Writing industrial applications

Automotive

• Cylinder Head Gaskets

Substrate Material: Alumina (aluminum oxide)
Product Name: Cotronics Resbond 940
Description: Used in high-temperature areas such as engine cylinder heads

Medical

• Autoclave Gaskets

Substrate Material: Stainless steel Product Name: Aremco Pyro-Putty 2400
Description: Used in autoclaves for sterilizing medical instruments, requiring high temperature and pressure resistance.

Chemical Industry

• Chemical Pump Gaskets

Substrate Material: Graphite
Product Name: Aremco Ceramabond 503
Description: Used in chemical pumps requiring corrosion and chemical resistance.

Food Industry

• Industrial Oven Gaskets

Substrate Material: Clay
Product Name: Aremco Ceramabond 571

Description: Used in industrial ovens for food production, providing high temperature resistance.

Pharmaceutical Industry

• Chemical Reactor Gaskets

Substrate Material: Alumina (aluminum oxide)
Product Name: Aremco Ceramabond 569
Description: Used in chemical reactors in the pharmaceutical industry, requiring high purity and chemical resistance.

Packaging Industry

• Packaging Machine Gaskets

Substrate Material: Stainless steel
Product Name: Aremco Ceramabond 571
Description: Used in packaging machines requiring high temperature resistance.

Electronics

• High-Temperature Device Gaskets

Substrate Material: Alumina (aluminum oxide)
Product Name: Aremco Ceramabond 503
Description: Used in electronics operating at high temperatures, such as electronic
furnaces.

Case study. The HydroGEN project – 3D printed sealing for solid oxide electrochemical cell stacks.

The HydroGEN project is a modular installation of reversible Solid Oxide Cells (rSOC), intended for integration into an industrial power plant to improve its flexibility of operation and increase the use of renewable energy sources in the hydrogen power sector. It is the brainchild of our partner, the Institute of Power Engineering (IEn).

Constructing the stack of solid oxide

electrochemical cells

HydroGEN is based on reversible solid oxide electrochemical cells operating alternately according to the power-to-gas (P2G) concept – in electrolyzer (SOE – Solid Oxide Electrolyser) and fuel cell (SOFC – Solid Oxide Fuel Cell) modes. The HydroGEN-based installation was designed and delivered by IEn in form of a container system integrated with EC Elbląg power plant within the Hydrogin project (realized by CBRF Energa Grupa Orlen and IMP PAN).

The sealing elements of the solid oxide cell stacks, manufactured by IEn, were made using a low-cost and waste-free 3D printing method on dedicated E-NIS machines designed and manufactured by Sygnis SA.

The role of seals in the stack

The seal used in order to separate the fuel and air zones inside the device is characterized by an ultra-low gas permeability coefficient. This requirement is met by glass-ceramic seals with strictly defined properties, optimized in the course of multivariate tests, which include: stability in oxidizing and reducing atmospheres over a wide range of partial pressures, resistance to thermal cycling over the life of the stack, compatibility of thermal expansion coefficient values with the parameters of other stack components, electrical insulation (preventing short-circuiting of cells in the stack), chemical compatibility with sealed components, as well as ease of manufacture and low cost.

The seals developed at the Institute of Power Engineering are made using an innovative method of 3D printing from glass paste using the E-NIS printers developed and manufactured by Sygnis SA. This is a low-cost and waste-free technology. The spatial printing technique allows the formation of a glass paste sealing material with appropriate rheological properties directly on the flat and corrugated surfaces of SOC stack elements. It also offers the possibility to build multilayer seals, thus allowing to optimize their thickness according to the application. Direct application of the seal to SOC stack components contributes to the elimination of redundant unit operations in the preparation of glass-ceramic seals and significant time savings, allowing the process to be more efficient and maintain its high repeatability.

The spatial printing technique allows the formation of a glass paste sealing material with appropriate rheological properties directly on the flat and corrugated surfaces of SOC stack elements. It also offers the possibility to build multilayer seals, thus allowing to optimize their thickness according to the application. Direct application of the seal to SOC stack components contributes to the elimination of redundant unit operations in the preparation of glass-ceramic seals and significant time savings, allowing the process to be more efficient and maintain its high repeatability.

3D printing allows for precise reproduction of the designed shape and ensures high quality and accuracy of the completed print. In addition, the use of waste-free 3D printing technology in the process of forming seals based on solid oxide electrochemical cells allows the production of seals with filler, patented by the Institute of Power Engineering. Such seals provide the required thickness and other gasket properties under equipment operating conditions, and are based on the use of, for example, waste ceramic powders from other industries as a sealing component.

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SILICONE for Direct Ink Writing (DIW)

Alex Kozlov — Sun, 25 Aug 2024 11:57:44 +0000

With a wealth of in-house expertise, our company excels in employing silicone for Direct Ink Writing (DIW) applications. Our successful collaborations with industry partners include printing gasket seals, harsh environment enclosures, thermal-insulating sockets and more. The utilization of 3D printing with silicone is revolutionizing diverse industries, leveraging silicone’s flexibility, biocompatibility, and durability. For example, in healthcare, medical-grade silicone is enhancing prosthetics and personalized implants, while automotive and aerospace sectors are benefiting from custom gaskets and seals. The process employs various techniques apart from DIW, including direct motor driven extrusion for precise layer-by-layer deposition and the use of silicone-based inks or pastes in inkjet.

Silicone Parameters:

UV-Cured:

• UV Acrylic: Offers fast curing times and excellent adhesion to various

substrates.

• UV Epoxy: Known for its high mechanical strength and resistance to

environmental factors.

• UV Acrylic-Urethane: Combines the flexibility of urethanes with the durability

of acrylics.

• UV-Curable Epoxy Resin: Provides a strong, durable finish with excellent

chemical resistance.

Moisture-Cured:

• Acidic: Cures quickly upon exposure to moisture, commonly used in

construction applications.

• Alcohol-Based: Offers a neutral cure with minimal odor and is suitable for a

wide range of materials.

• Acetoxy: Known for its fast curing time and strong adhesion, but releases

acetic acid during curing.

• Oxime: Provides a neutral cure, ideal for applications where corrosion of

metal substrates is a concern.

SILICONE for Direct Ink Writing industrial applications

Suction Cups for production lines

3D printing with silicones opens a new chapter in thinking about soft robotics, expands the possibilities to achieve complex geometries and speeds up the emergence of scientific breakthroughs.

It’s not just the domain of science – production lines also use a variety of grippers and manipulators. That’s why we have also decided to test the F-NIS – it turns out that it is an excellent machine also for the development of the science of soft robotics.

The seamless integration of F-NIS 23151 silicone 3D printing with metal elements represents a revolutionary approach to optimizing production lines. This innovative technology reinforces the reliability and longevity of suction cups and brings about many benefits for the production industry. Bellows and calyx suction cups have proven effective according to testing with robotic arms. These tests have showcased their unparalleled ability to meet the dynamic challenges posed by modern production environments. As a result, soft robotics in manufacturing has leaped forward, promising more efficiency, precision, and adaptability.

Using silicone as a printable material provides tremendous opportunities due to its exceptional elasticity and resistance to various environmental conditions. By F-NIS, we can create not only suction cups but also intricate structures and mechanisms using this revolutionary material.

Soft Gripper / 3D-printed soft robotics

We tested our F-NIS 23151 printed gripper with a robot arm and an egg. We handled it very carefully, examining the stability and gentleness of the material so as not to damage the delicate load. Incorporating F-NIS into our experiments has revealed its multifaceted capabilities and positioned it as an invaluable tool for promoting progress in the complex landscape of soft robotics.

Precision 3D Silicone Printing with F-NIS: Enhancing Soft Robotics. The decision to delve into the capabilities of F-NIS 23151 technology was born out of its impressive adaptability within the scientific community, making it a valuable asset for advancing the field of soft robotics. The potential of 3D silicone printing, propelled by F-NIS, reaches far beyond the confines of academic research. It finds tangible utility in the dynamic domain of soft robotics, where a diverse array of grippers and manipulators is pivotal in optimizing various industrial processes. The fusion of F-NIS technology with a robotic arm creates a mesmerizing synergy, emphasizing the delicate yet efficient art of manipulation. Through meticulous trials involving an egg, we shed light on the vast potential of this partnership. We carefully navigate the fine line between ensuring a secure grip on fragile cargo and preserving its inherent fragility. As soft robotics ventures into uncharted dimensions with 3D silicone printing, the adaptable F-NIS technology emerges as a versatile conduit. It serves as a catalyst for scientific advancement and an enabler of innovative solutions within industrial production. Positioned at the intersection of scientific exploration and industrial progress, the collaboration between F-NIS and soft robotics clears the path for groundbreaking research. It enhances the capabilities of production lines through the seamless integration of precision grippers.

Integrating F-NIS technology into 3D silicone printing has proven to be a transformative force in soft robotics and industrial applications. This collaborative journey has showcased the delicate balance between technology and fragility and the potential for F-NIS to revolutionize scientific research and production processes. With precision and care, F-NIS technology is paving the way for a future where soft robotics reaches new heights of efficiency and innovation.

Custom O-ring, Gaskets and Seals

Thanks to the ability to print virtually any type of silicone, F-NIS is a perfect tool for printing gaskets of all shapes and sizes. As creators of industrial machines and operators of an additive manufacturing production plant, we ourselves use this capability to produce custom-fit utensils for our needs.

F-NIS technology allows us to efficiently produce O-rings with complex cross-sections. This capability enables us to meet the specific demands of, for example, the automotive, aerospace, and medical industries, where precise and customized sealing solutions are crucial. By leveraging the flexibility of 3D printing, F-NIS empowers us to iterate and optimize the design of O-rings rapidly. This versatility eliminates the need for molds and production lines, enabling us to create individual functional seals on demand. For instance, we can manufacture industrial silicone seals that meet sanitary standards while maintaining total flexibility despite the layered structure inherent to 3D printing technology. Our iterative approach ensures our clients receive the most effective and reliable sealing solutions for their unique applications.

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