Geopolymeric formulations and associated methods for the manufacturing of three-dimensional structures

A method for manufacturing a three-dimensional solid structure, the method comprising:

• preparing an ink formulation for direct 3D printing, the ink formulation comprising a geopolymeric formulation in a fluid state, the geopolymeric formulation comprising:
• at least one inorganic compound comprising silicon and aluminum, the at least one inorganic compound selected from a group consisting of:
• a silicon-aluminate compound, a compound containing polysilicates, polysiloxane, polysilicon-aluminates and polysialates;
• and
• at least one alkaline activator and water;
• wherein the ingredients are present in such proportions as to undergo a geopolymerization reaction and produce, at an end of the geopolymerization reaction, a solid geopolymer;
• wherein, before and during at least a part of the geopolymerization reaction in which three-dimensional chemical bonds are not yet formed, the formulation reversibly forms a non-Newtonian, viscoelastic gel from a fluid;
• and
• wherein the formulation further comprises at least one geopolymerization reaction retarding agent, the retarding agent being present within the formulation in an amount between 0.1 and 5% by weight on the total weight;
• using the formulation as an ink for a direct 3D printing device which carries out an extrusion of the ink through a nozzle;
• and
• forming the three-dimensional solid structure upon a substrate mounted on the support by sequentially extruding upon said substrate strands of said ink.

A method for manufacturing a three-dimensional solid structure, the method comprising:

• preparing an ink formulation for direct 3D printing, the ink formulation comprising a geopolymeric formulation in a fluid state, the geopolymeric formulation comprising:
• at least one inorganic compound comprising silicon and aluminum, the at least one inorganic compound selected from a group consisting of:
• a silicon-aluminate compound, a compound containing polysilicates, polysiloxane, polysilicon-aluminates and polysialates;
• and
• at least one alkaline activator and water;
• wherein the ingredients are present in such proportions as to undergo a geopolymerization reaction and produce, at an end of the geopolymerization reaction, a solid geopolymer;
• wherein, before and during at least a part of the geopolymerization reaction in which three-dimensional chemical bonds are not yet formed, the formulation reversibly forms a non-Newtonian, viscoelastic gel from a fluid;
• and
• wherein the formulation further comprises at least one fluidifying agent, the fluidifying agent being present within the formulation in an amount between 0.1 and 5% by weight on the total weight;
• using the formulation as an ink for a direct 3D printing device which carries out an extrusion of the ink through a nozzle;
• and
• forming the three-dimensional solid structure upon a substrate mounted on the support by sequentially extruding upon said substrate strands of said ink.

A method for manufacturing a three-dimensional solid structure, the method comprising:

• preparing an ink formulation for direct 3D printing, the ink formulation comprising a geopolymeric formulation in a fluid state, the geopolymeric formulation comprising:
• at least one inorganic compound comprising silicon and aluminum, the at least one inorganic compound selected from a group consisting of:
• a silicon-aluminate compound, a compound containing polysilicates, polysiloxane, polysilicon-aluminates and polysialates;
• and
• at least one alkaline activator and water;
• wherein the ingredients are present in such proportions as to undergo a geopolymerization reaction and produce, at an end of the geopolymerization reaction, a solid geopolymer;
• wherein, before and during at least a part of the geopolymerization reaction in which three-dimensional chemical bonds are not yet formed, the formulation reversibly forms a non-Newtonian, viscoelastic gel from a fluid;
• and
• wherein the formulation further comprises at least one gelling agent, the gelling agent being present within the formulation in an amount between 0.1 and 20% by weight on the total weight;
• using the formulation as an ink for a direct 3D printing device which carries out an extrusion of the ink through a nozzle;
• and
• forming the three-dimensional solid structure upon a substrate mounted on the support by sequentially extruding upon said substrate strands of said ink.