Solid free-forming of ceramics using a continuous jet printer

A new method of manufacturing free-forming ceramics was investigated. Submicron titania powder was dispersed in a solvent-dispersant-resin-electrolyte system and used as a ceramic ink for a continuous jet printer with a nozzle diameter of 60 μm. Various fluid parameters such as viscosity and surface tension were investigated. The maximum viscosity which could be printed was found to be 30.2 mPa s. Contrary to work cited in the literature, surface tension was shown to have no effect on the formation or shape of the drops produced. Drop formation was shown to be consistent and reproducible. It was shown that the presence of agglomerated particles in the ink prevented the stream being modulated correctly. This resulted in a large number of stray drops being produced which resulted in a loss of resolution. The best dispersion of the ink was obtained by the use of an ultrasonic probe. This produced a homogeneous, well-dispersed ink which produced good quality printing. An ink with a ceramic volume loading of 3.99% was used to produce a number of free standing components by over printing layers.