SEMINAR: Self-standing, malleable doughs of advanced ceramics...

Guest: Özge Akbulut (Sabancı University)

Title: Self-standing, malleable doughs of advanced ceramics enable low-number production on a benchtop (MAT, ME, MFG)

Date/Time: Nov 27, 2024, 13:40

Location: FENS G035

Abstract: In product design, when we need long-term use, high thermal stability, high strength, and resistance to chemicals, we usually end up in a materials selection region that is covered by ceramics. On the other hand, these properties that single out ceramics for "extreme applications" are obstacles to conventional manufacturing methods, and most of the time, the uncomfortable outcome is settling for either a sub-optimal material or shape. At present, we do not have cost- and energy-effective, standard processing routes for ceramics that utilize current setups for rapid prototyping, and manufacturing in low numbers. There is a clear need for alternative methods that are specifically designed for ceramics. We generate self-standing doughs of advanced ceramics that can be shaped by hand, and via traditional and laser machining at the green state. We design particle-specific polymeric additives that homogeneously coagulate ceramic suspensions through polymer bridging, imparting a clay-like rheology to the suspensions of zirconia, alumina, magnesia, and many other technologically relevant ceramic systems. Starting from a self-standing structure that can withstand machining forces enables the exploitation of existing setups for machining of metals. The additive content in these formulations is less than 2 wt. %; the formulation can be reused, and the products reach >98% of the theoretical density after sintering. Recently, we have expanded our materials portfolio to nitrides (SiAlONs, more specifically), and our preliminary results on carbides and metals are promising. Large-scale imprinting and injection molding are also applicable. This “no-material leak” route offers an unprecedented, cost-effective scheme for prototyping and low-number production of ceramics.

Teaser videos: Roll-to-roll processing: https://vimeo.com/776127399

Milling: https://vimeo.com/756323910

Turning: https://vimeo.com/756325510

Bio: Ozge Akbulut is a faculty member at Sabancı University since 2012. She received her B.S. in Materials Science and Engineering at Sabancı University in 2004. Her PhD from Massachusetts Institute of Technology (2009) focused on cost-effective fabrication of biomolecular devices and surface science. She continued her studies as a post-doctoral fellow at Harvard University, (2009–2011) on developing tools/techniques for resource-limited settings. Her main research interests are silicone-based composites and additive/subtractive manufacturing of ceramics. She is the co-founder and CEO of Surgitate which designs and fabricates tactile surgical training platforms, since 2014. Starting from 2023, Dr. Akbulut also acts as a Chief Science Officer at Fark Labs—an innovation and transformation hub in the entrepreneurship ecosystem.