3D printing of polyblend calcium carbonate (grout) using binder jetting technology

Additive Manufacturing (AM) is a form of layered manufacturing. It utilizes a class of machines designed to recreate a physical structure from a 3-dimensional Computer-Aided Design (CAD) model by quick and highly automated means. The technology has gained a strong reputation in the aerospace and medical industries, and its use is now considered revolutionary in the construction industry. This research aimed at providing proof of the concept that polyblend calcium carbonate (grout) can be used as a material on a binder jetting 3D printer. In achieving the project objective tile specimens were constructed. This research investigated the effect of using different layer thickness, binder saturation levels, curing solutions and curing time on the 3D printed tiles. The deviation from nominal, the breaking strength, and surface roughness were measured and considered in determining the process parameters. The statistical analysis of the results indicated that the maximum breaking strength that tile specimens can reach is 2.98 KN. The minimum deviation in the Z direction of 0.01165” (0.3 mm) was observed when specimens were cured in an alkaline solution for 28 days. Moreover, lower surface roughness was obtained when the maximum binder saturation was used. One of the applications of this research is to 3D print mosaics and decorative tiles (PEI 0) since the achieved breaking strength exceed the ANSI (A137.1:2022) standard recommendation. These 3D-printed tiles can be used as ornamentation on walls in cottages, hotels, churches, and mosques. This research allows for the replication of precise replicas of historical façade to be used in restoring historical structures. In addition to that, high voltage insulators can be another area for future research by applying the finding of the proposed research.

Author

• Al Turk, Abdelhakim

Identifier

hdl:10057/28203

OAI identifier oai:identifier

oai:soar.wichita.edu:10057/28203