Study of alumina ceramic parts fabricated via DLP stereolithography using powders with different sizes and morphologies

Abstract Selecting suitable ceramic powders for the preparation of UV‐curable ceramic suspensions, which are well suited for printing processes and production of high‐performance ceramic components, is a crucial factor in the practical industrial application of digital light processing (DLP) stereolithography. Therefore, this study aims to provide a comprehensive evaluation of alumina ceramic parts fabricated via DLP stereolithography using a variety of alumina powders with varying sizes and morphologies. Experiments were conducted to examine the rheological response, recoating performance, and curing behavior of UV‐curable alumina suspensions. Additionally, the thermal decomposition behavior of three‐dimensional (3D)‐printed green‐bodies, as well as the physical and mechanical properties of 3D‐printed sintered alumina components were thoroughly investigated. The best physical and mechanical performances were achieved by printing 55 vol% suspensions prepared using near‐spherical AA04 alumina powders (median diameter .4 μm). This study elucidates the effects of ceramic particle size and morphology on the entire technological process of DLP‐based ceramic stereolithography, thereby establishing the guidelines for the fabrication of high‐performance 3D‐printed ceramic objects in industrial and engineering production by selecting appropriate ceramic powders.