Effect of the volume fraction of zirconia suspensions on the microstructure and physical properties of products produced by additive manufacturing

Kyoung-Jun Jang; Jin-Ho Kang; John G Fisher; Sang-Won Park

doi:10.1016/j.dental.2019.02.001

Effect of the volume fraction of zirconia suspensions on the microstructure and physical properties of products produced by additive manufacturing

Dent Mater. 2019 May;35(5):e97-e106. doi: 10.1016/j.dental.2019.02.001. Epub 2019 Mar 2.

Authors

Kyoung-Jun Jang¹, Jin-Ho Kang², John G Fisher³, Sang-Won Park⁴

Affiliations

¹ Department of Prosthodontics, School of Dentistry, Chonnam National University, Gwangju 61186, Republic of Korea. Electronic address: zircong@naver.com.
² Department of Prosthodontics, School of Dentistry, Chonnam National University, Gwangju 61186, Republic of Korea. Electronic address: dldigh8901@gmail.com.
³ School of Materials Science and Engineering, Chonnam National University, Gwangju, 61186, Republic of Korea. Electronic address: johnfisher@jnu.ac.kr.
⁴ Department of Prosthodontics, School of Dentistry, Chonnam National University, Gwangju 61186, Republic of Korea. Electronic address: psw320@chonnam.ac.kr.

PMID: 30833011
DOI: 10.1016/j.dental.2019.02.001

Abstract

Objective: The objectives of the present study were: (1) to analyze the dispersion and optical properties of suspensions with various volume fractions of zirconia, and (2) to assess the influence of zirconia volume fraction on the microstructure and physical properties of products produced by the additive manufacturing and sintering process.

Methods: Zirconia specimens were fabricated by an additive manufacturing technique using a DLP (digital light processing) system. The zirconia suspensions were divided into six groups based on zirconia volume fraction within the range of 48-58vol%.

Results: The maximum volume fraction of zirconia in suspensions possible for printing was 58vol%. The cure depth of the zirconia suspensions decreased as the volume fraction increased. The cure depth was greater than 100μm after 15s photocuring in all groups. Geometrical overgrowth tended to increase gradually as the volume fraction of zirconia increased within the range of 28.55-36.94%. The 3-point bending strength of the specimens increased as the volume fraction of zirconia in the suspension increased, reaching a maximum value of 674.74±32.35MPa for a volume fraction of 58vol%. Cracks were observed on the surfaces of zirconia specimens and these cracks increased in number as zirconia volume fraction decreased.

Significance: In this experiment, the viscosity of zirconia suspensions sharply increased from a volume fraction of 54vol%. Because of the very high viscosity, 58vol% was the maximum volume fraction possible for additive manufacturing. After polymerization, all specimens showed some distortion due to geometrical overgrowth. The maximum 3-point bending strength was 674.74±32.35MPa for a volume fraction of 58vol%. But the maximum strength of sintered zirconia prepared by additive manufacturing is inferior to that of conventionally sintered zirconia.

Keywords: Additive manufacturing; DLP (digital light processing); Rapid prototyping; Zirconia 3D printing; Zirconia photopolymer resin; Zirconia suspension.

Publication types

Research Support, Non-U.S. Gov't

MeSH terms

Ceramics*
Materials Testing
Microscopy, Electron, Scanning
Surface Properties
Suspensions
Zirconium*

Substances

Suspensions
Zirconium
zirconium oxide