Abstract
Stereolithography (SL) can fabricate complex ceramic parts layer by layer using computer-aided design (CAD) models. The traditional SL system utilizes a vat filled with ceramic slurry with a high solid content, which for ceramics contributes to several limitations and operational difficulties, and further renders it nonrecyclable mainly due to the presence of printed residue and its high viscosity. In this study, we utilized a continuous film supply (CFS) system integrated with a tape-casting type digital light processing (DLP) printer to fabricate zirconia prototypes with a solid content of 45 volume percent (vol.%). Various printing and postprocessing parameters were studied for optimization, to achieve a relative density of 99.02% ± 0.08% with a microhardness of 12.59 ± 0.47 GPa. Slurry reusability was also demonstrated by printing with recycled slurry to produce consistent relative density values in the range of 98.86% ± 0.02% to 98.94% ± 0.03%. This method provides new opportunities for material recycling and the fabrication of dense complex ceramic products, reducing the consumption of the material.
Highlights
They demonstrate a low affinity to bacterial plaque, limit inflammatory infiltration, and provide good soft-tissue integration
Another major issue in vat polymerization with ceramics is light scattering by ceramic particles, resulting in the unwanted overgrowth of features that affects cure depth and causes unexpected curing in bilateral directions [15,23,24,25,26,27]
The green printed state of ceramic material is fragile and lacking in the strength required to absorb the stresses involved in printing, making it susceptible to breakage during printing [28]
Summary
They demonstrate a low affinity to bacterial plaque, limit inflammatory infiltration, and provide good soft-tissue integration. The AM process can produce a variety of complex and intricate geometrical shapes simultaneously in a single workflow, without wasting machining tools and production time. With all these benefits, additively manufactured ceramic products are available using various technologies such as binder jetting, powder bed fusion, material extrusion, and vat polymerization [1,2,3]. Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations Another major issue in vat polymerization with ceramics is light scattering by ceramic particles, resulting in the unwanted overgrowth of features that affects cure depth and causes unexpected curing in bilateral directions [15,23,24,25,26,27]. Vat polymerization faces many challenges in the slurry dispensing system, which cannot accommodate a higher viscosity without wasting slurry and processing time [29]
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