Experimental studying on development of slurry-layer casting system for additive manufacturing of ceramics

  • Hsiao Chuan YenEmail author


Compared with powder-based process of additive manufacturing, slurry-based process can fabricate the ceramic components with better green density by casting thinner layers to improve the step effect. The main objective of this study is to develop a reliable slurry-layer casting system for building ceramic green parts. A premetered slurry-feeding mechanism was built to steadily supply the slurry and prevented the ripples on the layer from pulsation. Based on the techniques of slot-die coating and tape casting, a novel coater including a coat hanger distribution chamber and a doctor blade was designed and built to observe the distribution of the specified slurry and verify the feasibility of the slurry-layer casting. The experiment results revealed the distribution chamber with a suitable coat hanger angle that can uniformly deliver the slurry to the lips of the coater. The premetered coating method can simplify the process variables involved in the casting process. The slurry feeder exerts a considerable force on the slurry to overcome the influence of the viscosity. Sawtooth effect in the slurry-layer casting was observed and eliminated through the process of slurry preloading. Furthermore, an online coater cleanup device, which possesses the features of simple structure and high efficiency of residual slurry removal, was proposed. For the slurry with different formation used in the additive manufacturing of ceramic products, this study can be a pattern to build a reliable slurry-layer casting system with the principle of simple design, low cost, and easy cleanup.


Additive manufacturing Ceramic Slot-die coating Tape casting Slurry layer Sawtooth Step effect 


Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.


  1. 1.
    Mistler RE, Twiname ER (2000) Tape casting: theory and practice. Wiley, HobokenGoogle Scholar
  2. 2.
    Hotza D, Greil P (1995) Review: aqueous tape casting of ceramic powders. Mater Sci Eng A202:206–217CrossRefGoogle Scholar
  3. 3.
    Subramanian PK, Vail N, Barlow JW, Marcus HL (1995) Selective laser sintering of alumina with polymer binders. Rapid Prototyp J 1:24–35CrossRefGoogle Scholar
  4. 4.
    Liu ZH, Notle JJ, Packard JI, Hilmas G, Dogan F, Leu MC (2007) Selective laser sintering of high-density alumina ceramic parts. In: Proceedings of the 35th International MATADOR Conference, vol. 14. Taipei, Taiwan; pp. 351–354Google Scholar
  5. 5.
    Grau J, Moon J, Uhland S, Cima M, Sachs E (1997) High green density ceramic components fabricated by the slurry based 3DP process. In: Bourell DL et al. (ed) Proceedings of the 8th Solid Freeform Fabrication Symposium. Texas, USA, pp. 371–378Google Scholar
  6. 6.
    Bassoli E, Gatto A, Iuliano L, Violante MG (2007) 3D printing technique applied to rapid casting. Rapid Prototyp J 13:148–155CrossRefGoogle Scholar
  7. 7.
    Tian X, Li D, Heinrich JG (2012) Rapid prototyping of porcelain products by layer-wise slurry deposition (LSD) and direct laser sintering. Rapid Prototyp J 18:362–373CrossRefGoogle Scholar
  8. 8.
    Mühler T, Heinrich J, Gomes CM, Günster J (2013) Slurry-based additive manufacturing of ceramics. Int J Appl Ceram Technol. doi: 10.1111/ijac.12113 Google Scholar
  9. 9.
    Tang HH (2001) Method for rapid forming of a ceramic work piece. U.S. patent no. 6,217,816Google Scholar
  10. 10.
    Tang HH (2006) Building ultra-thin layers by ceramic laser sintering. Mater Trans J Jpn Inst Met 47:889–897Google Scholar
  11. 11.
    Tang HH, Liu FH (2005) Ceramic laser gelling. J Eur Ceram Soc 25:627–632CrossRefGoogle Scholar
  12. 12.
    Yen HC (2012) A new shape-developing process for fabricating ceramic green part by selective laser scanning the gelled green layer. J Eur Ceram Soc 32:3123–3128CrossRefGoogle Scholar
  13. 13.
    Durst F, Wagner H-G (1997) Slot coating. In: Kistler SF, Schweizer PM (eds) Liquid film coating. Chapman & Hall, London, pp 401–426CrossRefGoogle Scholar
  14. 14.
    Lin YY, Wu PY, Liu TJ, Hsu TC, Tiu C (2013) Coating die design for suspensions. Asia-Pac J Chem Eng 8:115–129CrossRefGoogle Scholar
  15. 15.
    Carvalho MS, Kheshgi HS (2000) Low-flow limit in slot coating: theory and experiments. AICHE J 46:1907–1917CrossRefGoogle Scholar
  16. 16.
    Yen HC, Tang HH (2008) Developing a paving system for fabricating ultra-thin layers. Int J Adv Manuf Technol 36:280–287CrossRefGoogle Scholar
  17. 17.
    Lippert HG (2006) Slot die coating for low viscosity fluids, pp19-1∼19-15 Coatings technology handbook, 3rd edition—fundamentals—testing, and processing techniques, Tracton AA (ed), CRC Press, Taylor & Francis Group, Boca Raton, FL 33487–2742, USAGoogle Scholar

Copyright information

© Springer-Verlag London 2014

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringNational Taipei University of TechnologyTaipeiTaiwan

Personalised recommendations