Evaluation and optimisation of a slurry-based layer casting process in additive manufacturing using multiphase simulations and spatial reconstruction

Abstract Slurry-based 3D printing allows ceramic green bodies to be fabricated at high packing densities. In contrast powder-based binder jetting, full densification of printed parts can achieved in a subsequent sintering step as fine particles dispersed suspension are cast and compacted. is thus expected overcome the application limits alternative metal casting terms unfavorable properties like surface roughness, low density mechanical strength. To ensure stress-free drying therefore qualities compounds made layers, it crucial fabricate single layers with level homogeneity. This paper presents CFD model based on open-source simulation environment OpenFOAM predict resulting homogeneity slurry layer defined parameter sets or coater geometries using Volume-Of-Fluid method. Moreover, novel method spatial reconstruction proposed evaluate quality minimised computional demand. By comparing results real macroscopic behaviour determined experiments, approach found useful tool for suggesting suitable parameters processing slurries. A precise outline coating area different process an approximate prediction effect roughness was achieved.