Additive manufacturing (AM) has gained significant attention due to its ability to drive technological development as a sustainable, flexible, and customizable manufacturing scheme. Among the various AM techniques, direct ink writing (DIW) has emerged as the most versatile 3D printing technique for the broadest range of materials. DIW allows printing of practically any material, as long as the precursor ink can be engineered to demonstrate appropriate rheological behavior. This technique acts as a unique pathway to introduce design freedom, multifunctionality, and stability simultaneously into its printed structures. Here, a comprehensive review of DIW of complex 3D structures from various materials, including polymers, ceramics, glass, cement, graphene, metals, and their combinations through multimaterial printing is presented. The review begins with an overview of the fundamentals of ink rheology, followed by an in‐depth discussion of the various methods to tailor the ink for DIW of different classes of materials. Then, the diverse applications of DIW ranging from electronics to food to biomedical industries are discussed. Finally, the current challenges and limitations of this technique are highlighted, followed by its prospects as a guideline toward possible futuristic innovations.

Direct Ink Writing: A 3D Printing Technology for Diverse Materials

Conversion of inorganic-organic frameworks (ceramic precursors and ceramic-polymer mixtures) into solid mass ceramic structures based on photopolymerization process is currently receiving plentiful attention in the field of additive manufacturing (3D printing). Various techniques (e.g., stereolithography, digital light processing, and two-photon polymerization) that are compatible with this strategy have so far been widely investigated. This is due to their cost-viability, flexibility, and ability to design and manufacture complex geometric structures. Different platforms related to these techniques have been developed too, in order to meet up with modern technology demand. Most relevant to this review are the challenges faced by the researchers in using these 3D printing techniques for the fabrication of ceramic structures. These challenges often range from shape shrinkage, mass loss, poor densification, cracking, weak mechanical performance to undesirable surface roughness of the final ceramic structures. This is due to the brittle nature of ceramic materials. Based on the summary and discussion on the current progress of material-technique correlation available, here we show the significance of material composition and printing processes in addressing these challenges. The use of appropriate solid loading, solvent, and preceramic polymers in forming slurries is suggested as steps in the right direction. Techniques are indicated as another factor playing vital roles and their selection and development are suggested as plausible ways to remove these barriers.

/pdf/photopolymerization-based-additive-manufacturing-of-ceramics-1odk2eio7i.pdf

Photopolymerization-based additive manufacturing of ceramics: A systematic review

Along with vast research on the additive manufacturing (AM) of polymeric and metallic materials, three-dimensional (3D) manufacturing of ceramic materials is now the modern trend. Among all the additive manufacturing techniques, Direct Ink Writing (DIW) permits the ease of design and rapid manufacturing of ceramic-based materials in complicated geometries. This paper presents an outline of the contributions and tasks in the fabrication 3D ceramic parts by the DIW technique. The current state-of-the-art manufacturing of various ceramics such as alumina, zirconia, and their composites through Direct Ink Writing (DIW) is described in detail. Moreover, this review paper aims at the innovations in the DIW approach of ceramic materials and introduces the progression of the DIW for the manufacturing of ceramics. Most importantly, the DIW technique has been explained in detail with illustrations. The prospects and challenges related to the DIW technique are also underscored.

Direct ink writing (DIW) of structural and functional ceramics: Recent achievements and future challenges

The reconstruction or repair of oral and maxillofacial functionalities and aesthetics is a priority for patients affected by tooth loss, congenital defects, trauma deformities, or various dental diseases. Therefore, in dental medicine, tissue reconstruction represents a major interest in oral and maxillofacial surgery, periodontics, orthodontics, endodontics, and even daily clinical practice. The current clinical approaches involve a vast array of techniques ranging from the traditional use of tissue grafts to the most innovative regenerative procedures, such as tissue engineering. In recent decades, a wide range of both artificial and natural biomaterials and scaffolds, genes, stem cells isolated from the mouth area (dental follicle, deciduous teeth, periodontal ligament, dental pulp, salivary glands, and adipose tissue), and various growth factors have been tested in tissue engineering approaches in dentistry, with many being proven successful. However, to fully eliminate the problems of traditional bone and tissue reconstruction in dentistry, continuous research is needed. Based on a recent literature review, this paper creates a picture of current innovative strategies applying dental stem cells for tissue regeneration in different dental fields and maxillofacial surgery, and offers detailed information regarding the available scientific data and practical applications.

https://www.mdpi.com/1996-1944/13/22/5303/pdf

Advanced Biomaterials and Techniques for Oral Tissue Engineering and Regeneration-A Review.

Bone replacement materials used in tissue engineering require a high degree of safety and biological compatibility. For these reasons synthetic bone replacement materials based on calcium-phosphates are being used more widely. To mimic natural bone, rapid prototyping processes and especially 3D printing are favourable. Using 3D printing, complex 3 dimensional structures can be made easily. In this study we successfully performed biocompatibility tests with a Hydroxyapatite test structure (HA-S) made by 3D printing. Cytotoxicity tests were carried out according to DIN ISO 10993-5 in static and dynamic cultivation setups. To estimate cell proliferation and analyze morphology, histological evaluation was done. In summary, good cell viability as well as good proliferation behaviour were found. Moreover, these results show that the 3D printing process in combination with the suitable material presented in this study is well suited for fabricating scaffolds for TE in the required

Biocompatibility of ceramic scaffolds for bone replacement made by 3D printing Biokompatibilitat 3D gedruckter keramischer Scaffolds als Knochenersatz

Additive manufacturing of advanced ceramic materials

Direct ink writing – an extrusion-based additive manufacturing process – followed by pressureless sintering was investigated to produce boron carbide monoliths. The effects of ceramic powder loading and Pluronic binder concentration on the rheology of boron carbide pastes were studied and linked to both processing behaviour and final outcome in terms of sintered density and hardness. The effects of printing parameters, in particular orifice diameter and printing speed, were also investigated. Reducing the size of the extrusion nozzle from 584 μm to 406 μm led to significantly better shape retention, lower surface roughness, as well as higher density and hardness. A 203 μm printing orifice was also trialled but was unsuccessful due to faster drying kinetics that occurred with smaller ceramic struts resulting in rapid warping and nozzle clogging. Carbon-black – 8 wt% relative to B4C – acted as an effective sintering aid to increase both density and hardness. After optimisation of feedstock and printing parameters, few-layer samples (3–5 layers) had a density as high as ∼ 97 % TD and a hardness of ∼ 30 GPa. On the other hand, 18-layer specimens had a sintered density of ∼ 87 % TD, despite a fully dense microstructure, due to the formation of a 3D array of inter-strut pores. Nevertheless, several issues that arose during manufacturing and post-processing were detrimental to the density and structural integrity of printed specimens; these issues were identified, discussed, and suggestions for future work are provided.

Direct ink writing of boron carbide monoliths

UV-curable silicone materials with tuneable mechanical properties for 3D printing

Dispersion and stability of colloidal boron carbide suspensions

Silicone cellular foams are well suited for energy absorbing applications due to their ability to undertake large deformations and absorb significant quantities of energy. However traditional methods for fabrication of cellular silicone are long and difficult and with no possibility of varying the density of pores. Having a fabrication method that allows controlling the structure hence mechanical properties of the silicone features is essential for expanding their application.

Anna Terry

Papers

Additive manufacturing of advanced ceramic materials

Direct ink writing of boron carbide monoliths

UV-curable silicone materials with tuneable mechanical properties for 3D printing

Dispersion and stability of colloidal boron carbide suspensions

Development of 3D cellular silicone structures using reactive inkjet printing approach for energy absorbing application