Abstract
A reliable method for fabricating zirconia-based all-ceramic teeth by stereolithography with gelcasting was demonstrated. The effects of ZrO2 particle size were studied on the stability and rheological properties of the zirconia slurry. The effects of powder properties, slurry solid content and sintering temperature on the properties and microstructure of zirconia were also investigated. The results showed that optimal parameters were: 0.2 µm particle size, solid phase content 37 vol% of zirconia slurry and sintering temperature 1550 °C. Part density was up to 98.6%, flexural strength was 1170 MPa and fracture toughness was 19.0 MPa m1/2. Zirconia-based all-ceramic teeth were finally fabricated based on the optimal parameters by using combined stereolithography with gelcasting.
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