Viscoelastic characterization and extrusion performance of a novel ink for metal direct ink writing

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dc.authorid0000-0002-9378-3870
dc.authorid0000-0003-0665-8041
dc.contributor.authorErcan, Necati
dc.contributor.authorSaray, Onur
dc.contributor.authorParlak, Mahmut Ekrem
dc.date.accessioned2026-02-08T15:15:40Z
dc.date.available2026-02-08T15:15:40Z
dc.date.issued2025
dc.departmentBursa Teknik Üniversitesi
dc.description.abstractPurposeThis study aims to improve the extrudability and stability of polyvinyl alcohol-polyethylene glycol (PVA-PEG)-based water-soluble binders by modifying their composition with carboxymethyl cellulose (CMC). The primary objective is to determine the optimal CMC concentration that enhances critical solid loading capacity, suppresses binder segregation and phase separation and promotes stable and consistent extrusion. Furthermore, this work seeks to establish quantitative relationships between the rheological properties and extrudability of inks to be used in Direct Ink Writing.Design/methodology/approachA comprehensive analysis of the physical, rheological and mechanical behavior of CMC-modified binders was conducted. Rheological characterization involved the assessment of zero-shear viscosity, extrusion viscosity, yield stress, storage modulus, loss modulus and phase angle. An innovative extrusion testing setup was developed to simulate Solvent Cast Direct Ink Writing (SC-DIW) process conditions, enabling real-time detection of flow instabilities such as clogging and phase separation. The optimum solid loading range was determined based on extrusion force profiles. In addition, three-point bending tests were performed on green parts to evaluate mechanical strength and validate interlayer cohesion after extrusion.FindingsThe results show a CMC concentration of 1.5 Wt.% improves the stability of the PVA-PEG binder, preventing phase decomposition and separation and ensuring stable flow. The critical powder loading ratio for the binder with 1.5 Wt.% CMC was determined to be within the range of 85-87.5 wt. Moreover, an optimal balance of extrudability and post-extrusion green part strength can be achieved using a binder containing 1.5 Wt.% CMC. In addition, a successful extrusion process can be achieved using CMC-modified binders when G ', tau y, mu ex and mu 0 are lower than 3 x 105 Pa, 820 Pa, 100 Pa.s and 50,000 Pa.s., with alpha values ranging from 0.5 to 0.6.Originality/valueThis research introduces a novel strategy for stabilizing PVA-PEG-based binders by integrating CMC to suppress phase decomposition and separation and improve extrudability in SC-DIW processes. This study provides, for the first time, a predictive framework linking rheological thresholds to extrusion performance through a custom-designed extrusion simulation test. Findings of this study are expected to significantly advance the design of high-solid-loading inks for extrusion-based metal additive manufacturing.
dc.description.sponsorshipScientific and Technological Research Council of Turkiye (TUBITAK) [119C069]; TUBITAK Scientist Support Programs Directorate (BIDEB)
dc.description.sponsorshipThis research was supported by the Scientific and Technological Research Council of Turkiye (TUBITAK) under the 2244 Project with grant number 119C069, and we gratefully acknowledge TUBITAK for their contributions. Authors also wish to express their gratitude to Ermetal Otomotiv ve Esya Sanayi Tic. A.S. for their financial and laboratory support within the scope of the 2244-Industry Doctoral Program conducted by the TUBITAK Scientist Support Programs Directorate (BIDEB), with special thanks to Mr. Fatih Ates for his dedicated assistance. They also extend their thanks to the Department of Food Engineering at Bursa Technical University for providing laboratory facilities, and to Assoc. Prof Dr Furkan Turker Sar & imath;caoglu for his valuable support. Finally, the authors would like to thank the Project Support Office of Bursa Technical University for their assistance in proofreading this manuscript.
dc.identifier.doi10.1108/RPJ-09-2024-0386
dc.identifier.endpage2086
dc.identifier.issn1355-2546
dc.identifier.issn1758-7670
dc.identifier.issue9
dc.identifier.scopus2-s2.0-105014874183
dc.identifier.scopusqualityQ1
dc.identifier.startpage2068
dc.identifier.urihttps://doi.org/10.1108/RPJ-09-2024-0386
dc.identifier.urihttps://hdl.handle.net/20.500.12885/5888
dc.identifier.volume31
dc.identifier.wosWOS:001611803200011
dc.identifier.wosqualityQ1
dc.indekslendigikaynakWeb of Science
dc.indekslendigikaynakScopus
dc.language.isoen
dc.publisherEmerald Group Publishing Ltd
dc.relation.ispartofRapid Prototyping Journal
dc.relation.publicationcategoryMakale - Uluslararası Hakemli Dergi - Kurum Öğretim Elemanı
dc.rightsinfo:eu-repo/semantics/closedAccess
dc.snmzWOS_KA_20260207
dc.subjectAdditive manufacturing
dc.subjectDirect ink writing
dc.subjectRheology
dc.subjectViscoelastic characterization
dc.subjectExtrudability test
dc.subjectPhase separation
dc.subjectGreen part strength
dc.titleViscoelastic characterization and extrusion performance of a novel ink for metal direct ink writing
dc.typeArticle

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