Extrusie gebaseerde additieve productie met keramische en metalen filamenten van componenten bestaande uit één of meerdere materialen

This doctoral program develops a process chain of additively manufacturing metal or ceramic components with filament-based Material Extrusion (MEX). The process chain includes filament production, printing investigation, post process (debinding & sintering) and further characterisation on single material components of metal as well as ceramic. In particular, the developed process chain is further applied to multi-material parts, with the target application in electrical motors. The research started with investigating the printing process of commercial filaments (copper, iron silicon, zirconia) using design and experiments, analysis of variance and further characterisation. The optimised printing strategies resulted in enhanced physical properties of sintered parts. In addition, two mathematic models were developed for the solvent debinding process to improve the entire process efficiency. Subsequently, preliminary tests of manufacturing multi-material parts with commercial filaments revealed a critical challenge due to the mismatched sintering behaviour of copper and zirconia. Therefore, this work further developed a binder system and a novel ceramic grade to produce on-house filaments. They further built-up prototypes of multi-material parts of copper and zirconia. The sintered multi-material parts exhibited improved quality from the ones with commercial filaments. The developed feedstocks successfully proved the feasibility of manufacturing multi-material components via filament-based MEX, despite the minor mismatch of sintering shrinkage.