CHEMICAL ENGINEERING JOURNAL
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2026
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IF 12.5
Qing Qin,Zihan Guo,Runze Liu,Siran Yin,Gang Xiong,Zhen Shen,Xiaojun Zeng,Changchun Ge
Digital light processing (DLP) technology offers great promise for fabricating geometrically intricate silicon nitride (Si 3 N 4 ) ceramics, yet its advancement has been persistently constrained by the intrinsic challenge of formulating slurries that simultaneously enable high solid loading and low viscosity. This work presents a synergistic strategy that effectively resolves this bottleneck. Our approach integrates optimized physical packing (coarse/fine of 3:7) with precise colloidal interface engineering, employing a novel acrylate-modified block copolymer (KMT-3510) in conjunction with a short-chain dispersant (BYK-9076). Mechanistic insights reveal that the polar groups (C O and ester C O) of KMT-3510 form strong hydrogen bonds with the Si 3 N 4 surface, while its hydrophobic alkane chains (C H) extend into the resin matrix, establishing a robust steric hindrance barrier. This synergistic dispersion enabled a Si 3 N 4 slurry with a high solid loading of 60 vol% and a low viscosity of 3.10 Pa·s at 12 s −1 , demonstrating excellent rheological performance. Using this high-solid-loading slurry, fully dense ceramic parts were successfully fabricated via DLP, followed by debinding and gas-pressure sintering at 1800 °C. The sintered ceramics inherited excellent mechanical properties, including a flexural strength (742 ± 24 MPa), Vickers hardness (16.8 ± 1.6 GPa), and fracture toughness (5.02 ± 0.34 MPa·m 1/2 ). Microstructural analysis indicated that the high toughness originates from the synergistic activation of multiple toughening mechanisms, such as crack deflection, grain bridging, and β -Si 3 N 4 grain pull-out. This work provides a clear and effective slurry design pathway for the DLP-based fabrication of high-performance Si 3 N 4 ceramics with complex geometries.
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Biomaterials Advances
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2025
·
IF 6
Lei Zhan,Boqing Zhang,Hongyun Wo,Lina Wu,Huan Li,Min Liu,Zhuangzhuang Li,Tao Chen,Xingyu Gui,Kaixin Wang,Xiaobing Pu,Changchun Zhou
The aging population and the increasing prevalence of sports-related injuries have made osteochondral defects a major global health issue. The repair of osteochondral defect is still a challenge due to poor regeneration of both cartilage and bone tissues. To address this issue, this study developed a biomimetic dual-layer scaffold based on SilMA hydrogel using DLP technology. For the upper area of scaffold, PEGDA was used to enhance the mechanical strength of SilMA hydrogel, making it more suitable for the environment of articular cartilage, while cell microspheres were incorporated as 3D carriers for chondrocyte encapsulation and delivery, providing seed cells for regeneration. For the lower area of scaffold, the lower part was loaded with hydroxyapatite to promote bone tissue regeneration. This study systematically investigated the design of 3D printable inks for osteochondral defect repair, exploring the effects of PEGDA and HAp on the printability and physicochemical properties of SilMA bioink through orthogonal experiments. In vitro and in vivo results demonstrated that the biomimetic dual-layer scaffold exhibited good biocompatibility, promoting cell adhesion and proliferation. Thus, these dual-layer scaffolds loaded with chondrocyte microspheres effectively promote the synchronous repair of both articular cartilage and subchondral bone.
研究领域:
生物医学工程
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组织工程
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再生医学
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CERAMICS INTERNATIONAL
·
2025
·
IF 5.6
Yi-Ning He,Ren-Zhong Zhang,Jia-Min Wu,Ze-Yu Deng,Ze-Yuan Li,Jia-Xin Zheng,Lin Guo,Zhi-Xiang Cai,Yu-sheng Shi
SiO 2 -based ceramics are an ideal material for manufacturing radomes due to their thermal stability, high dielectric properties, and simple processing techniques. However, traditional manufacturing methods heavily rely on molds, making it difficult to form complex SiO 2 -based ceramic structures. Digital Light Processing (DLP) technology was applied to fabricate SiO 2 -based ceramics doped with Al 2 O 3 -MgO in this work. The influence of the Al 2 O 3 -MgO content on the SiO 2 -based ceramics was systematically investigated. Increasing Al 2 O 3 -MgO content causes a shrinkage to first decrease then increase, contrasting with the flexural strength's initial increase and subsequent decrease. The main reason is magnesium-aluminum spinel (MgAl 2 O 4 ) generated during the sintering process and thus retards crack propagation, promoting a transition in fracture mode. During the fracture stage, the fracture mode of samples with 10.0 wt% Al 2 O 3 -MgO is mainly transgranular fracture, instead of intergranular. This transition in fracture mode enhanced the flexural strength. Meanwhile, as the Al 2 O 3 -MgO content continues to increase, excessive spinel causes agglomeration within the ceramic microstructure. When the Al 2 O 3 -MgO content reached 10.0 wt%, the shrinkage decreases to a minimum of 3.32 %, and the flexural strength increases to a maximum of 15.94 MPa, making it suitable for manufacturing ceramic radomes. The research results provide a new solution for manufacturing SiO 2 -based ceramic radomes by DLP.
研究领域:
陶瓷材料
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增材制造
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材料科学
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材料电学性能
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微观结构调控
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Journal of the Mechanical Behavior of Biomedical Materials
·
2024
·
IF 3.3
Yanlong Wu,Xu Chen,Jianfeng Kang,Yongqiang Yang,Xin Zhao,Yaxiong Liu,Jian Qiao
Calcium silicate can be used as an excellent material for biodegradable bone scaffolds because it can provide bioactive ions to promote bone regeneration. However, the brittleness and rapid degradation of calcium silicate scaffolds have significantly limited their clinical application. In this work, the calcium silicate scaffolds printed by DLP technology were immersed in a gelatin solution under high vacuum condition to obtain calcium silicate/gelatin composite scaffolds with good mechanical and biological properties. Then, genipin was used as a cross-linker for gelatin to control the degradation properties of the composite scaffolds. The initial compressive strength and toughness of the composite scaffolds were 5.0 times and one order of magnitude higher than those of the pure calcium silicate scaffolds, respectively. The gelatin on the surface of the scaffolds could effectively act as a protective layer to regulate the degradation behaviors of the calcium silicate substrate through controlling the crosslinking degree of the gelatin. After degrading for 14 days, the composite scaffolds at 1.0 % genipin concentration exhibited the highest compressive strength of 8.6 ± 0.8 MPa, much higher than that of the pure ceramic scaffold (1.5 ± 0.3 MPa). It can be found that the toughness of the composite scaffolds were almost over 13.2 times higher than that of the pure ceramic scaffold during degradation, despite the higher toughness loss for the former. Furthermore, the composite scaffolds showed enhanced cell biocompatibility and viability. These results demonstrate that the calcium silicate/gelatin composite scaffolds can be a promising candidate in bone tissue regeneration .
研究领域:
生物材料
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组织工程
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生物医学工程
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材料科学
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Polymers
·
2024
·Vol. 16
·期 8
·1148
·
IF 4.7
Velmurugan Senthooran,Zixiang Weng,Lixin Wu
Digital light processing (DLP) techniques are widely employed in various engineering and design fields, particularly additive manufacturing. Acrylate resins utilized in DLP processes are well known for their versatility, which enables the production of defect-free 3D-printed products with excellent mechanical properties. This study aims to improve the mechanical and thermal properties of 3D-printed samples by incorporating mica as an inorganic filler at different concentrations (5%, 10%, and 15%) and optimizing the dispersion by adding a KH570 silane coupling agent. In this study, mica was introduced as a filler and combined with epoxy acrylate resin to fabricate a 3D-printed sample. Varying concentrations of mica (5%, 10%, and 15%w/w) were mixed with the epoxy acrylate resin at a concentration of 10%, demonstrating a tensile strength increase of 85% and a flexural strength increase of 132%. Additionally, thermal characteristics were analyzed using thermogravimetric analysis (TGA), and successful morphological investigations were conducted using scanning electron microscopy (SEM). Digital light-processing technology was selected for its printing accuracy and cost-effectiveness. The results encompass comprehensive studies of the mechanical, thermal, and morphological aspects that contribute to the advancement of additive manufacturing technology.
研究领域:
材料科学
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增材制造
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JOURNAL OF ALLOYS AND COMPOUNDS
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2026
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IF 6.7
Dawei Guan,Xi Chen,Donghong Wang,Qingxiao Yu,Yaozhong Zhang,Xiaofu Liu,Fei Li
Hollow turbine blades are critical components of aircraft engines, and their performance strongly depends on the dimensional stability and mechanical reliability of ceramic cores during casting. Although most previous studies have focused on the behavior of ceramic cores during the heating and holding stages at casting temperatures, cracks and deformation may also develop during cooling, during which phase transformations can significantly affect the quality of blade castings. In this study, silica ceramic cores with a commercial composition were fabricated by DLP 3D printing, and their phase transformation behavior and evolution of high-temperature mechanical properties during cooling were systematically investigated. SEM and XRD results showed that β-cristobalite gradually transformed into tridymite during cooling. This transformation was accompanied by volume expansion, which compressed cracks and promoted their closure. Correspondingly, the high-temperature flexural strength increased with decreasing temperature and eventually stabilized at 36 ± 0.4 MPa, while the tridymite content exhibited a similar trend and reached 6.5 wt.%. In addition, approximately 0.7–0.9 wt.% of zircon decomposed into zirconia and silica phases at high temperature. These findings demonstrate that the phase transformation and associated microstructural evolution during cooling are closely related to the enhancement of the high-temperature flexural strength of silica ceramic cores.
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CERAMICS INTERNATIONAL
·
2023
·
IF 5.2
Mengting Dang,Xuezheng Yue,Guohong Zhou,Song Hu
Alumina ceramics with optimized microstructures and mechanical properties were obtained by the attractive digital lighting processing (DLP) additive manufacturing methodology in the present study. A acrylate-based resin system was designed for the alumina powders with a mean particle size of 0.5 μm. The influence of oligomer on the viscosity and polymerization kinetics of the ceramic suspensions has been elaborately discussed by rheology, curing depth and photo-DSC characterizations. The results indicated that the introduction of oligomer has improved the cross-linking density of resins and decreased the critical dose of energy for resin polymerization, which contributed to a tougher ceramic-resin slice with higher dimensional accuracy. Densifying processes including debinding and high temperature sintering of the ceramic parts were conducted according to the TG-DTA characterizations, alumina ceramics with uniform microstructures and eliminated delamination or intralaminar cracks were finally obtained. The flexural strength was 471 MPa for the ceramics obtained from the resin composition containing 20 wt% oligomer, Weibull modulus for the ceramics were determined to be 17.31 by evaluating thirty all sides polished ceramics, indicating the highly uniform property of the ceramics fabricated by DLP additive manufacturing.
研究领域:
材料科学
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化学工程
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CERAMICS INTERNATIONAL
·
2023
·
IF 5.2
Yang Wang,Qingxuan Zhou,Zhuoqun Han,Yongning Han,Lunan Bi,Xia Zhang,Xiang Lu,Jie Zhao,Wei Chu,Jian Li,Zhicheng Zhao,Yingying Wang,Jia Liu,Ling Li,Futian Liu
ZrO 2 –Al 2 O 3 (ATZ) ceramics are attracting high interest in biomedical applications because of their desirable mechanical performance and biocompatibility. However, strength and toughness are mutually exclusive in structural ceramics . In this paper, based on digital light processing, novel textured ATZ ceramics with obvious crystallographic orientations were fabricated by incorporating Al 2 O 3 platelets with a high aspect ratio and equiaxed particles into the ZrO 2 matrix. The optimized fracture toughness of 16.9 ± 0.8 MPa m 1/2 was achieved in the textured ATZ ceramic, which was about 67.3 % higher than non-textured ZrO 2 ceramics, without sacrificing strength. The coupling toughening effects of macrolayer structure, equiaxed and platelet-shaped Al 2 O 3 particles, and ZrO 2 particles were responsible for the enhanced mechanical performance. The macroscale toughening of 3D-printed lamellar architecture led to effective energy dissipation. Additionally, the crack deflection and crack branching induced by dual-morphology Al 2 O 3 particles, accompanied by the phase transformation of the ZrO 2 matrix, were significant microscopic toughening mechanisms.
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COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING
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2025
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IF 8.9
Sung-Jun Lee,Eunwon Choi,Ji-Young Choi,Chang-Lae Kim
This study presents the development of piezoresistive pressure sensors based on Ti 3 C 2 T x MXene-coated polyurethane (PU) sponges fabricated using Digital Light Processing (DLP) 3D printing. Six different porous structures were designed by varying the line width (300 and 500 μm) and height width (100, 300, and 500 μm) to optimize the sensor performance. The 500 × 300 μm structure demonstrated an optimal balance between sensitivity and measurement range, achieving resistance change rates from −11.02 % at 25 Pa to −163.78 % at 2.25 kPa. DLP 3D printing allows precise control of pore geometry with dimensional accuracy within 50 μm, while eliminating the complex multistep fabrication processes associated with traditional template methods. The sensor exhibited excellent durability, with less than 1.5 % performance variation after 1000 compression cycles at both 1 and 2 kPa values. Environmental stability tests revealed minimal interference from humidity (30–90 % RH) and predictable temperature-dependent behavior (20–90 °C). Cytotoxicity assessments using RAW 264.7 macrophages confirmed biocompatibility, with cell viability exceeding 95 % for both MAX/MXene materials and PU/MXene composites. Practical demonstrations, including finger pressing, palm contact, and dynamic tapping, validated the capability of the sensor for human motion detection. The combination of DLP 3D printing precision and MXene conductivity enables the scalable production of customizable pressure sensors for wearable electronics, health monitoring, and human–machine interface applications.
研究领域:
生物医学工程
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柔性电子学
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纳米材料科学
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智能穿戴技术
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人机交互
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健康监测
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JOURNAL OF THE EUROPEAN CERAMIC SOCIETY
·
2026
·Vol. 47
·期 3
·118870
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IF 6.3
Dajun Xu,Yanwei Huang,Liang Cai,Biao Yi,Yingjie Guo,Guangfan Tan,Zhen Shen,Yingchun Zhang
The influence of plasticizer PEG300 on the rheological and curing properties of AlN suspensions was firstly investigated. • The synergistic effect between plasticizer PEG300 and dispersant BYK110 was investigated. • The impact of debinding schedules on the properties of DLP-printed AlN ceramics was clarified. • The quality factor ( Q×f) was firstly introduced as a key evaluation metric for AlN ceramics in ceramic substrate. In this study, Digital Light Processing (DLP) was used to fabricate aluminum nitride (AlN) ceramics for electronic ceramic substrate. To address the two extreme issues of poor rheology and poor photocuring ability of slurry, the high-performance 50 vol% AlN suspensions were prepared through the combined use of the dispersant polyphosphoester and plasticizer PEG300. Meanwhile, to overcome the challenge of removing the excess organic matter from the 3D-printed green bodies, the optimal debinding and sintering schedule was established: debinding in a vacuum environment firstly, next decarburization is performed in air atmosphere, followed by final sintering in N 2 sintering furnace. Under this schedule, the AlN ceramics achieve the relative density of 99.3%, flexural strength of 344 ± 5 MPa, thermal conductivity of 172.5 W/(m·K). Furthermore, dielectric properties were evaluated in this work: the AlN ceramics exhibited optimal dielectric performance of ε r = 8.36, tan δ = 1.22 × 10 −3 at 14.3 GHz ( Q×f = 11754.6 GHz).
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Small
·
2026
·
IF 11.8
Jinghan Qiao,Chunyang Zhang,Fulin Huai,Shengjie Zhang,Baihong Chi,Kuan Lu,Pengfei Wang,Mengzhu Li,Ya Kong,Jun Nie,Guiping Ma
The performance of structural electromagnetic absorbers critically depends on the dielectric matrix, which demands low permittivity, low loss, high mechanical strength, and good processability. However, traditional high-performance dielectrics, typically formed by hot pressing, cannot be fabricated with complex architectures precisely. Photocurable 3D printing resins offer high precision but suffer from inadequate thermal stability, wave transparency, and structural reliability, limiting their practical use. In this work, a novel isocyanate-functionalized monomer was designed and synthesized to construct a photo-thermal curable low dielectric resin system. This resin enables rapid curing and shape fixation under UV irradiation, followed by secondary crosslinking during post-thermal treatment, resulting in a dense and stable 3D network. The cured resin maintains a low dielectric constant (ε′ < 3.0) and low dielectric loss (tan δ < 0.01) in the X-band, while exhibiting notable enhanced thermal stability (T g > 200°C) and mechanical performance (tensile strength > 80 MPa). A dielectric honeycomb scaffold was subsequently fabricated via 3D printing, into which graphene-CoFe 2 O 4 powders were introduced, together with a conductive silver layer cured at the bottom. The resulting composite achieved a minimum reflection loss of −59.8 dB at a thickness of only 1.93 mm in the X-band.
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ACS Applied Materials & Interfaces
·
2025
·
IF 8.2
Yan Li,Chunrui Peng,Haoxiao Liang,Dongxing Zhang,Tao Wu,Qiuquan Guo,Junfeng Xiao,Peipei Jia,Jun Yang
Polytetrafluoroethylene (PTFE) is renowned for its exceptional chemical inertness and hydrophobicity. However, the high melt viscosity, low surface energy, and high cooling shrinkage of PTFE make it difficult to fabricate fine three-dimensional (3D) structures through photopolymerization molding. Meanwhile, due to the mechanical properties of PTFE, such as low hardness and low elastic modulus, the wear resistance of its structure is usually poor. In this study, we propose an effective strategy to enhance both wear resistance and superhydrophobicity in 3D-printed PTFE/C structures by controlling the carbon residue during the sintering process. To achieve the refined structure of PTFE, a photo-cross-linkable PTFE/PEGDA ink was developed, in which PEGDA acts as a photocurable scaffold to enable high-resolution DLP printing of PTFE nanoparticles. Furthermore, inspired by the microarray of cicada wings, a needle-repellent structure with a water contact angle (CA) exceeding 150° was printed using a PTFE-based ink. Based on the above structure, the carbon residue in PTFE/PEGDA was controlled by the sintering process to further enhance the wear resistance and superhydrophobicity of the structure. These results indicated that the sintered needle-repellent structure can still maintain excellent hydrophobic properties with 1000-grit sandpaper under a load of 100 g for 20 cycles. The performance conflict between superhydrophobicity and wear resistance of the PTFE/C structure has been effectively alleviated through the printed needle-repellent structure and controlled carbon residue. Furthermore, even after 2 weeks of immersion in strongly acidic and alkaline environments, the structure morphology remains stable. These excellent features of the needle-repellent structure make it applicable to a wide range of applications, such as droplet manipulation, oil–water separation, and fog harvesting.
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