Ceramic 3D printing tests - What?

10.06.13 – 20.06.13

Oslo National Academy of the Arts (KHIO)

 

In April, I was invited over to KHIO to give a lecture about my work and to meet the staff in both the ceramics and D-Form departments. Paul Scott, one of my colleagues in MIRIAD is a Professor 2 at KHIO and had the idea to arrange a collaborative venture around the theme of ceramics and print, something that has been a specialism of his for a number of years. However, the planned event is to focus on the 3D printing of ceramics, something that Trine Wester who runs the D-Form 3D printing facility has started to explore.

Back in Manchester, we have acquired 2 ZCorp 406 3D printers, both in need of restoration. The plan is to restore one of them and use it to continue the ceramic printing experiments. Whilst I am waiting for the printer to be housed in a suitable room, I thought a very good use of my time was to head back to Oslo to learn about using ZCorp printers by working with the D-Form team. This time I was keen to explore the ceramic powder that Potclays had developed for 3D printing. I purchased 15 kgs, which just fitted into a small suitcase and passed through airport security without any questions!

On the Monday morning we made a good start by moving the printer, de-powdering unit and computer down into the ceramics department.

The plan was to test and compare red earthenware with the Potclays powder. The recipes are as follows:

RED CLAY	POTCLAYS	ICING SUGAR	MALTODEXTRIN
2		1	1
3		1	1
4		1	1
	2	1	1
	3	1	1
	4	1	1

Each batch was prepared in 3kg batches. Once printed the tests would be fired in batches to 950°, 1000°, 1050° and 1100°C.

I designed a small test bar with a precise 100mm slot in the top to be used to accurately measure shrinkage.

On Tuesday morning the first tests were printed.

There follows a description of how the printer was prepared:

1. Compacting the powder.

2. Levelling the powder

3. Filling the binder tank with zp61 binder fluid

4. Cleaning the print head parking dock with distilled water.

 5. Purging the HP10 print head of ink and 
 bleeding the binder tube for air bubbles.

6. Cleaning the print head 'pogos' with an alcohol swab.
(Squeeze the tube to release the alcohol)

 

7. Print settings, 
(note the Bleed Compensation is checked).

8. Powder settings, note that in all other 
tests the Shell was 90% and the Core was 85%

9. Printing the binder, (note some ink still visible).

10. Potclays 1:1:4 powder, smoother
 and finer than the red earthenware.

Tomorrow we print more Potclays powder variations, so that the firings can commence on Friday.

More to follow...