Ceramic freeforming using an advanced multinozzle ink-jet printer

A high performance, multinozzle, piezoelectric drop-on-demand ink-jet printer was used for solid freeforming of ceramics by direct, multiple-layer printing of suspensions of a commercially available powder. The wide-array print head was arranged over a single-axis stepper-motor driven table. Ceramic inks were prepared using low-polarity solvents to give low-ink conductivity and, hence, prevent corrosion of the electroding system in the print head. Zirconia inks were prepared in a high-energy bead mill charged with 500 mum diameter zirconia media. The procedure for selecting solvent, dispersant, resin and their proportions is discussed in the context of print quality. The surface quality and fracture surfaces of three-dimensional (3-D) sintered zirconia test coupons were studied by microscopy. The fracture surfaces showed no sign of droplet relics and could not be used to detect the method of powder assembly.