Research Projects

Functionally Graded Materials (FGMs) and multimaterials (MMs) have become integral in diverse applications, delivering graded advantages across various structural components. Widely adopted in aerospace, microelectronics, and biomedical implants, FGMs and MMs with gradient properties offer targeted protection to critical aerospace components exposed to high temperatures and localized deterioration. Recent advancements, such as the utilization of Alumina and Aluminium alloys for engine components and rocket nozzles, underscore the exceptional heat and corrosion resistance achieved through FGMs. The synergy between multiple materials, such as bioceramics, is advantageous for biomedical applications, although the fabrication of such next-generation materials poses challenges in terms of complexity and cost. This study addresses these challenges by leveraging coaxial extrusion-based Additive Manufacturing (AM). Although laser-based AM methods exhibit limitations in the fabrication and control of ceramic multi-materials result in high residual stresses, poor surface finish, and densification coupled with high operational costs. In contrast, extrusion 3D Printing and Sintering (E3DPS) has emerged as a cost-effective alternative that ensures controlled porosity, superior surface finish, and enhanced microstructure control. The proposed process development encompasses the fabrication of diverse materials, ranging from single to multimaterial to FGMs. The synergy between extrusion-based 3D printing and sintering will be explored to create MMs/FGMs for biomedical applications. This project involves preparing pastes of hydroxyapatite (HaP)/zirconia (ZrO2) and Tricalcium Phosphate (TCP) (ceramic/ceramic) for 3D printing, optimizing rheological behaviors, and employing a syringe-based dispensing system to precisely control the material composition. TCP acts as a porous soft and highly biocompatible material inside and HaP/ ZrO2 dense acts as a tough material outside. The debinding and sintering parameters will be refined to achieve a high sintered density, with a comprehensive study of the mechanical and biomedical properties of various FGM designs. The proposed data-driven finite element modelling approach can help predict the density and shape deformation due to gravity during the sintering of FGM materials. This will help designers optimize the shape by predicting the density and deformation before the experiments. To the best of our knowledge, this pioneering research represents a unique endeavor in India. The proposed methodology aims to fabricate high-efficiency, complex-shaped, multi-material FGM for biomedical applications and further extend it to metal/ceramic multi-materials. The potential impacts include the prospect of patent filings and publications in high-impact journals. Collaborative efforts with medical laboratories in the future will ensure real-world validation technology transfer envisaged for startup initiation under SINE IITB.