Improvement of Processability Characteristics of Porcelain-Based Formulations Toward the Utilization of 3D Printing Technology

A study of the feasibility of porcelain-based formulations for 3D printing was performed. Based on commercial materials characterization, the binder jetting process properties requirements were defined. Porcelain powder-based formulations were prepared and evaluated with different binder solutions. The powder-binder formulations were characterized (e.g., particle size distribution and wettability of powder, viscosity and surface tension of liquid binder) and showed some different and similar characteristics when compared with commercial materials. The addition of solid (sodium alginate, sucrose) and liquid (glycerol, ethanol) additives in the powder-binder composition improved the experimental printed tests. The effect of binder composition and operating process parameters (binder saturation level, bleed compensation, and printed layer thickness) was analyzed and optimized to obtain a printed saucer with different designs. Results revealed some limitations related to the materials and the technology, thus justifying the introduction of technological improvements. This study showed the possibility to process industrial porcelain powders by additive manufacturing, paving the way for a new development challenge in the productive process of ceramic products.