Ceramic On-Demand Extrusion (CODE) is an additive manufacturing process cultivated to facilitate the construction of dense ceramic components leveraging high solid loading aqueous pastes. In our recent endeavors, we have championed advancements in CODE. Our meticulous studies encompass the pioneering creation of microchannels for compact heat exchangers using a precise blend of ZrB2-SiC aqueous paste, extending to the exploration of ultra-efficient power generation systems.
We have significantly expanded the horizons of the CODE process to facilitate the crafting of 3 mol% yttria-stabilized zirconia components, equipped with support structures created using organic feedstocks, thereby unveiling potentials in building complex geometrical parts with promising mechanical attributes. Our efforts have seen the CODE process reaching unprecedented heights in mechanical resilience, outpacing several other additive manufacturing techniques, evidenced through comprehensive ASTM standard test techniques.
Our detailed investigations also shed light on the versatility of the CODE process, manipulating the solid content and drying mechanisms to construct large ceramic parts with complex geometries while maintaining near theoretical density. This included integrating sapphire optical fiber sensors within the ceramic constructs during the fabrication process, a strategy aimed to obviate the challenges posed by traditional sensor embedment techniques.
Furthermore, we have ingeniously utilized inorganic sacrificial material such as CaCO₃ for crafting intricate support structures, a step augmenting the potential applications significantly. As we forge ahead, our focus remains steadfast on augmenting the efficiency, and broadening the applicative horizon of the CODE process, anchoring on its promising attributes of creating highly dense, geometrically complex, yet mechanically robust ceramic components.
We extend an invitation for you to join our endeavor as we explore uncharted territories in the realm of CODE technology.
Recent Publications
2022
Rafi, Abid Hasan, Marharyta Lakusta, Vincenzo Anthony, Grace Basler, Sophie Grier, Lauren Moeller, David Lipke, Jeremy Lee Watts, Greg Hilmas, and Ming C. Leu. “Ceramic On-Demand Extrusion of ZrB2-SiC Microchannels for Ultra High-Temperature Compact Heat Exchanger.” In 2022 International Solid Freeform Fabrication Symposium. 2022.
2020
Li, Wenbin, Amir Armani, Devin McMillen, Ming Leu, Gregory Hilmas, and Jeremy Watts. “Additive manufacturing of zirconia parts with organic sacrificial supports.” International Journal of Applied Ceramic Technology 17, no. 4 (2020): 1544-1553.
2018
Li, Wenbin, Amir Ghazanfari, Devin McMillen, Ming C. Leu, Gregory E. Hilmas, and Jeremy Watts. “Characterization of zirconia specimens fabricated by ceramic on-demand extrusion.” Ceramics International 44, no. 11 (2018): 12245-12252.
Martin, Austin J., Wenbin Li, Jeremy Lee Watts, Ming-Chuan Leu, Greg Hilmas, and T. Huang. “Mitigating Coffee-Ring Defect Formation in Ceramic On-Demand Extrusion Parts.” 2018 International Solid Freeform Fabrication Symposium 2018.
2017
Ghazanfari, Amir, Wenbin Li, Ming C. Leu, and Gregory E. Hilmas. “A novel freeform extrusion fabrication process for producing solid ceramic components with uniform layered radiation drying.” Additive Manufacturing 15 (2017): 102-112.
Ghazanfari, Amir, Wenbin Li, Ming Leu, Jeremy Watts, and Gregory Hilmas. “Mechanical characterization of parts produced by ceramic on‐demand extrusion process.” International Journal of Applied Ceramic Technology 14, no. 3 (2017): 486-494.
Ghazanfari, Amir, Wenbin Li, Ming C. Leu, Jeremy L. Watts, and Gregory E. Hilmas. “Additive manufacturing and mechanical characterization of high density fully stabilized zirconia.” Ceramics International 43, no. 8 (2017): 6082-6088.
Li, Wenbin, Amir Ghazanfari, Ming C. Leu, and Robert G. Landers. “Extrusion-on-demand methods for high solids loading ceramic paste in freeform extrusion fabrication.” Virtual and Physical Prototyping 12, no. 3 (2017): 193-205.
Li, Wenbin, Amir Ghazanfari, Devin McMillen, Ming C. Leu, Gregory E. Hilmas, and Jeremy Watts. “Fabricating ceramic components with water dissolvable support structures by the Ceramic On-Demand Extrusion process.” CIRP Annals 66, no. 1 (2017): 225-228.
2016
Ghazanfari, Amir, Wenbin Li, Ming C. Leu, Yiyang Zhuang, and Jie Huang. “Advanced ceramic components with embedded sapphire optical fiber sensors for high temperature applications.” Materials & Design 112 (2016): 197-206.