Process parameter optimization for alumina ceramic parts manufactured by fused deposition modelling

What is it about?

The study recommends the adoption of structured parameter optimization workflows to support industrial integration of ceramic FDM and highlights the need for future work on optimizing debinding and sintering profiles to improve final part stability Ceramic materials are gaining relevance in Additive Manufacturing (AM), although the lack of standardized process parameters limits the repeatability and comparability of printed parts. This study proposes an optimization procedure for the fabrication of alumina (Al₂O₃) components using Fused Deposition Modelling (FDM) with a ceramic–polymer composite filament. The methodology was structured in two phases. First, the printing parameters related to extrusion conditions, speed profiles, layer configuration, and infill strategies were iteratively optimized using green parts. Then, the influence of chemical debinding and sintering was considered to refine the geometric parameters and scale factors necessary to ensure dimensional stability in final ceramic parts. The optimized parameter set was evaluated by fabricating standardized test artifacts according to ISO 52902:2023 to assess dimensional accuracy, resolution, and surface finish, and results were benchmarked against polylactic acid (PLA) printed under optimal conditions. The findings show that the proposed procedure enables reliable fabrication of alumina parts and provides objective performance data; however, dimensional deviations and surface artifacts increase after sintering due to material shrinkage and thermal deformation

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Why is it important?

The comparison made with PLA and Al2O3 allowed the following conclusions to be drawn: • The data obtained from both the linear artifacts and the Z-axis artifacts made of Al2O3 do not achieve the precision reached in those corresponding to the PLA parts. • Regarding achievable resolution, the additive manufacturing system using FDM performs better for PLA-manufactured artifacts than for Al2O3. PLA allows the creation of smaller features than the filament used in this study, whereas, in the case of alumina, the dimensional reduction that occurs during the sintering operation negatively affects features that both the slicer software and the printer can process but ultimately disappear in the post-process. • As a result of the post-printing operations (chemical and thermal), all the Al2O3 parts have undergone some kind of warping, which has altered the original geometry of the parts. • Surface finishes are substantially better in the PLA-manufactured artifact, with the geometry of the Al2O3 piece not materializing when the part reaches an overhang with an inclination greater than 65°.

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