Recent advances in the stereolithographic three-dimensional printing of ceramic cores: Challenges and prospects

Abstract

The increasing demand for geometrically complex structures—specifically, higher-inlet-temperature turbine blades for the fifth-generation or other high-generation machines of advanced fighter aircrafts—has made the development of more complex double-walled three-layer hollow-cavity structures a necessity. However, this requires the preparation of complex ceramic cores and advanced, integrated technologies. Stereolithographic three-dimensional printing (SLA-3DP) technology, with digital control upon material morphology, composition, and structure, is a high integration and versatile technique that is superior to the traditional manufacturing techniques for ceramic cores, including gel casting, injection molding, and hot pressing. The latent capacity of this technique is contingent on the progress of processing routes that significantly reduce the distortion and defect formation in response to the elimination of the reacted organic monomer phase during photo-curing. Despite the tremendous progress in the field, multiple challenges remain, such as the preparation of high-solid-content and low-viscosity suspensions, SLA-3DP of large double-walled ceramic cores with complex structures, and process optimization and sinter strengthening for the fabrication of ceramic cores. These challenges have prevented the broader applications and reduced the impact of the SLA-3DP technology. This review discusses cutting-edge research on the crucial factors governing this production method. Specifically, we outline the existing challenges within the field and provide our perspective on the upcoming research work and progress.