High-performance zirconia ceramic additively manufactured via NanoParticle Jetting

Additive manufacturing has received tremendous attention in the manufacturing and materials industry in the past three decades. Zirconia-based advanced ceramics have been the subject of substantial interest related to structural and functional ceramics. NanoParticle Jetting (NPJ), a novel material jetting process for selectively depositing nanoparticles, is capable of fabricating dense zirconia components with a highlydetailed surface, precisely controllable shrinkage, and remarkable mechanical properties. The use of NPJ greatly improves the 3D printing process and increases the printing accuracy. An investigation into the performance of NPJ-printed ceramic components evaluated the physical and mechanical properties and microstructure. The experimental results suggested that the NPJ-fabricated ZrO2 cuboids exhibited a high relative density of 99.5%, a glossy surface with minimum roughness of 0.33 μm, a general linear shrinkage factor of 17.47%, acceptable hardness of 12.43 ± 0.09 GPa, outstanding fracture toughness of 7.52 ± 0.34 MPa m1/2, comparable flexural strength of 699 ± 104 MPa, dense grain distribution of the microstructure, and representative features of the fracture. Subsequently, the exclusive printing scheme that achieved these favorable properties was analyzed. The innovative NanoParticle Jetting™ system was shown to have significant potential for additive manufacturing.