Freeform Fabrication of Ceramics via Stereolithography

TLDR

Stereolithography can produce ceramic green bodies by suspending 0.40–0.55 vol % ceramic powder in a UV‑curable resin. The authors mixed silica, alumina, or silicon nitride powders into a UV‑curable resin, photocured the suspension layer by layer to build a green body, and then removed the binder to sinter the ceramic part. They successfully fabricated 3‑D objects from a 0.50 vol % silica suspension.

Abstract

Ceramic green bodies can be created using stereolithography methods where a ceramic suspension consisting of 0.40–0.55 volume fraction ceramic powder is dispersed within an ultraviolet‐curable solution. Three ceramic materials were investigated: silica for investment casting purposes, and alumina and silicon nitride for structural parts. After mixing the powders in the curable solution, the ceramic suspension is photocured, layer by layer, fabricating a three‐dimensional ceramic green body. Subsequent binder removal results in a sintered ceramic part. Three‐dimensional objects have been fabricated from a 0.50 volume fraction silica suspension.