Assessment of the Surface Texture of the Prototype Produced by DIW-3D-Printing Process Using Methyl Cellulose-Based Aluminum Ink

Direct ink writing (DIW) is a versatile 3D printing technique capable of fabricating complex structures with precise control over geometry and material composition. However, optimizing ink formulations to balance structural integrity, surface quality, and manufacturability remains a challenge. This study aims to investigate the microstructure, morphology, and retention properties of prototypes produced using methyl cellulose (MC)-based alumina (Al 2 O 3 ) inks with varying solid loadings (35 wt.%, 50 wt.%, and 65 wt.%). The printing ink was prepared by blending MC with Al 2 O 3 , and the designs were modeled using CATIA V5 R21 software. 3D printing was conducted via Ultimaker Cura, with its specifications modified for compatibility. Prototypes with different geometries were fabricated and analyzed for structural retention, surface properties, and microstructures. Results indicate that structural retention improves with increased solid loading, achieving maximum retention at 65 wt.%. However, surface roughness also increases with higher solid loading, with 50 wt.% providing the optimal balance for smooth surface finishes. The mechanical strength and microstructure of all prototypes were enhanced through post-processing via sintering. This study contributes to advancing DIW technology by establishing relationships between solid loading, structural performance, and surface quality, thereby providing insights for tailoring ink formulations for specific applications.