Fabrication of soluble salt-based support for suspended ceramic structure by layered extrusion forming method

Abstract

The support material is necessary to prevent the collapse of the suspended structure when forming complex ceramic parts via layered extrusion forming (LEF, a type of additive manufacturing) method, and needs to be removed easily after sintering. In this work, salt-based slurries were prepared with magnesium sulfate monohydrate (MSM) and polyvinyl pyrrolidone (PVP) in order to solve the problem of extrusion and removal of the support material. The effect of the solid content on the rheological performance of slurries and the printing quality of specimens was studied. The results showed that the salt-based slurry containing 60 wt% MSM and 10 wt% PVP powder possessed shear-thinning behavior and the corresponding samples held sufficient bending strength and superior surface quality, which satisfied the requirements for the support structures in LEF method. After calcination at different temperature, the salt-based support structure could be easily removed, which offers an alternative support material choice for the LEF method. Keywords: Layered extrusion forming, Salt-based slurry, Magnesium sulfate, Rheology, Soluble support material