Abstract
A 3YSZ (3 mol% yttria-stabilized zirconia) ceramic green body with 50 vol% of ceramic content was 3D-printed by supportless stereolithography under optimal drying, debinding, and sintering conditions in order to achieve high strength and density. The viscosity and flowability of the ceramic nanocomposite resins were optimized by adjusting the amounts of non-reactive diluents. The ceramic 3D-printed objects have a high polymer content compared to ceramics samples manufactured by conventional manufacturing processes, and the attraction between layers is weak because of the layer-by-layer additive method. This causes problems such as layer separation and cracking due to internal stress generated when materials such as solvents and polymers are separated from the objects during the drying and debinding processes; therefore, the drying and debinding conditions of 3YSZ ceramic 3D-printed objects were optimized based on thermogravimetry–differential thermal analysis. The sintering conditions at various temperatures and times were analyzed using X-ray diffraction, SEM, and flexural strength analysis, and the body of the 3YSZ ceramic 3D-printed object that sintered at 1450 °C for 150 min had a relative density of 99.95% and flexural strength of 1008.5 MPa. This study widens the possibility of manufacturing ceramic 3D-printed objects with complex shapes, remarkable strength, and unique functionality, enabling their application in various industrial fields.
Highlights
Ceramic products are used in various fields such as electronics, aerospace, and biotechnology owing to their excellent strength and unique functionality [1,2,3]
All the 3 mol% yttriastabilized zirconia (3YSZ) nanocomposite resins showed similar exothermic curves for 60 s, and the total photopolymerization amount increased with increasing Bu content
A 3YSZ 3D-printed sintered body with a high relative density of 99.95% and high flexural strength of 1008.5 MPa was manufactured by supportless stereolithography apparatus (SLA) 3D printing technology
Summary
Ceramic products are used in various fields such as electronics, aerospace, and biotechnology owing to their excellent strength and unique functionality [1,2,3]. Engineering applications generally require ZrO2 ceramics with complex geometric shapes, but the high brittleness and hardness of ZrO2 ceramics make it difficult to produce complex-shaped parts by traditional methods [5]. The SLA method involves a layer-by-layer buildup of a photopolymer resin in a desired shape by irradiation with a UV laser or a digital light processing projector. Compared to other AM methods, SLA is more commonly used in various fields such as medical implants and mechanical microparts, where high-precision parts are required [7] owing to its fast printing speed and high precision. Several studies on the SLA printing method have been reported for manufacturing high-strength ceramic 3Dprinted objects by dispersing ceramic particles such as Al2 O3 and ZrO2 in a photopolymer base resin [8,9]. The ceramic 3D printing method can produce complex and various shapes of ceramic parts that cannot be manufactured by conventional ceramic processes such
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