Additive manufacturing of metal-ceramic-composites by thermoplastic 3D-printing (3DTP)

In our new approach – thermoplastic 3D printing (3DTP) – high-filled ceramic and metal feedstocks based on thermoplastic binder systems were used to produce metal-ceramic-composites by means of additive manufacturing (AM). The developed AM method has some outstanding advantages compared to other methods. First, the portfolio of applicable materials is not limited. Second, it works almost independently of the properties of the dispersed material. The application of thermoplastic 3D printing with two components is in principle demonstrated with stainless-steel-zirconia composites. Different feedstocks with high powder content up to 50 vol% were prepared. The main challenge was the adjustment of the shrinkage behavior for the different materials, which could be achieved by high-energy milling and the adjustment of the powder content within the metal feedstock. The adapted additive manufacturing method of thermoplastic 3D printing (3DTP) offers new prospects for the fabrication of multi-material components. This AM method will be applicable not only for steel-zirconia composites but also for any other combinations of materials that can be processed to a paraffin-based thermoplastic feedstock and co-sintered