A comprehensive study on zirconia slurry for stereolithography-based additive manufacturing

Abstract: Stereolithography-based additive manufacturing (AM) makes it possible to realize high-quality ceramic parts with various shapes. However, preparation of ceramic slurry with high solid loading, low viscosity, long-term stability, and desirable cure depth for stereolithography is still challenging. In this paper, research is carried out for revealing the effects of dispersant, solid loading, and mixing method on the stability and viscosity of the slurry. Under optimized conditions, a highly stable yttria-stabilized zirconia ceramic slurry with high solid loading (45 vol.%) was prepared by grinding with a three-roller mill. With layer thickness of 30 μm and exposure dose of 10 mJ/cm² (10 mW/cm² for 1 s), ceramic green bodies with complex shape were successfully fabricated. After sintering, the final ceramic parts showed well-defined shapes with high level of densification. Graphical Abstract: [Figure not available: see fulltext.].