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My academic journey began during my undergraduate studies in Materials Engineering at the Federal University of Paraíba (Paraíba, Brazil). In my second year, I became involved in Undergraduate Research projects focused on replacing conventional raw materials in traditional ceramic products—such as tiles— and reusing industrial waste generated by the local ceramic industry (Northeast Brazil). This early research experience sparked my interest in scientific inquiry and motivated me to continue to get a master’s degree and, now a Ph.D., where I specialize in the additive manufacturing (AM or 3D printing) of ceramic materials using the extrusion-based technique known as Direct Ink Writing (DIW).

While AM of polymers and metals is already well-established and widely applied in industry, ceramic 3D printing still faces several challenges. These include formulating inks with suitable rheological behavior, ensuring the production of parts with structural integrity, and carrying out post-processing steps, such as drying and sintering, to achieve the desired final properties. As such, ceramic AM remains a dynamic and evolving research field with great potential for advanced technological applications.

Various technologies exist for the additive manufacturing of ceramics, each with specific characteristics depending on the raw materials, resolution requirements, and target applications. Among them, the DIW technique—also known as robocasting—stands out for its simplicity, low cost, and versatility regarding printable formulations. It enables the fabrication of parts with a wide range of geometries and compositions, as long as the inks possess the necessary rheological behavior. However, DIW still presents key challenges, particularly in maintaining dimensional stability of the filaments during and after extrusion, and in achieving precise rheological control to ensure continuous flow, shape retention, and geometric fidelity. My current research project addresses these challenges by investigating the printability of ceramic pastes – specifically the relationship between rheological properties and printing parameters – with a focus on filament shape retention. The goal is to develop optimized ceramic formulations based on alumina and mullite for advanced applications in technical ceramics, electronics, aerospace, and more.

 Examples of qualitative tests to assess the printability of alumina-based filaments produced by Direct Ink Writing.

Working with ceramic materials for 3D printing via DIW has been both challenging and rewarding. The work demands precise tuning of multiple parameters, such as solid content, additive selection and dosage, and viscosity and yield stress, to achieve stable extrusion and robust shape retention after deposition. Even small variations in the formulation or processing can lead to issues like structural collapse, resolution loss, or clogging of the printing system. Despite these complexities, these challenges make the research all more stimulating, offering opportunities for innovation and meaningful contributions to the advancement of ceramic additive manufacturing.

I am also a member of the Multidisciplinary Study Group in Ceramic Engineering (Grupo de Estudos Multidisciplinares em Engenharia Cerâmica – GEMEC), part of the Department of Materials Engineering at UFSCar. led by Prof. Dr. Ana Paula da Luz. Our group conducts research across several areas of ceramic engineering, with strong emphasis on additive manufacturing, refractory materials, and geopolymers. We believe that the exchange of knowledge and collaboration are vital to scientific progress. Please, feel free to get in touch—it will be a great pleasure to establish new partnerships and research collaborations.

Thiago Wisley Barbosa de Farias

PhD Candidate

Graduate Program in Materials Science and Engineering
Federal University of São Carlos, UFSCar - Brazil.

e-mail: twbfarias@estudante.ufscar.br

linkedin: https://www.linkedin.com/in/thiagowisley/