Sintering Protocol Research Articles

Impact of speed sintering on the mechanical and optical properties of multilayered zirconia

Speed sintering techniques have been introduced to shorten the sintering time of zirconia ceramics, yet their impact on multilayered zirconia properties remains understudied. The purpose of this in vitro study was to assess the effect of speed sintering on the optical properties and the mechanical flexural strength of multilayered zirconia materials. A total of 360 disks (Ø14 ±2 mm ×1.2 ±0.02 mm) were fabricated by following the International Organization for Standardization (ISO) 6872:2015 standard using 2 types of Vita A2 shade multilayered zirconia materials: IPS e.max ZirCAD Prime (ZP) and IPS e.max ZirCAD Prime Esthetic (ZPE). Each material comprised translucent (Tr), gradient l (Gr), and dentin (De) layers, with 60 disks per layer. Half were sintered using a standard sintering protocol and half using a speed sintering protocol. Biaxial flexural strength was accessed using a universal testing machine equipped with the Blue Hill Universal software program by following the ISO 6872:2015 standard, with 20 disks per subgroup. The spectrophotometric analysis of optical properties (contrast ratio [CR], translucency parameter [TP], and total transmittance [Tt%]) was performed using a dual-beam spectrophotometer (Ultrascan VIS) in accordance with the ISO 7491:2000 standard, with 10 disks per subgroup. The comparison of the optical properties and the mechanical flexural strength between the speed and standard protocol was analyzed using an unpaired t test (α=.05). Speed sintering reduced biaxial flexural strength in all ZP layers (P<.05) and in ZPE-Gr (P<.05). A statistically significant difference in the CR was observed in the ZP-Tr, ZP-Gr, and ZPE-Gr layers (P<.05). The TP of the ZP-Gr, ZP-De, and ZPE-Gr layers was significantly lower when using the speed sintering protocol. Tt% was significantly lower with speed sintering for both materials (P<.05). Speed sintering statistically changed both the optical (CR, TP, Tt%) and mechanical (flexural strength) properties of multilayered zirconia materials, but the differences may not be clinically relevant.

Impact of Sintering Protocol of Hydrothermally-aged High-translucent Zirconia Materials

Impact of Sintering Protocol of Hydrothermally-aged High-translucent Zirconia Materials

Effect of sintering cycle on the strength and translucency of multilayered zirconia.

A newly introduced sintering protocol promises to offer higher translucency while not significantly compromising the flexural strength of the material. However, the effect of the novel sintering protocol has not been thoroughly validated. The purpose of this study was to measure and compare the effect of two sintering protocols on the translucency and flexural strength of two multilayered zirconia materials. Two types of multilayered zirconia materials (ZirCAD Prime and Prime esthetic) were selected. Presintered disk specimens were obtained from Translucent, Gradient, and Dentin layers (n = 20). The disks were allocated to 2 groups: standard sintering protocol (peak temperature 1500°C) and high translucency sintering protocol (peak temperature 1600°C). After the sintering process, 10 specimens from each group were randomly selected. The optical values (L*, a*, b*) were measured and used to assess translucency using the relative translucency parameter (RTP00) and translucency differences (ΔRTP00). Then, all 20 specimens were tested for biaxial flexural strength. The outcomes were analyzed. The analysis of variance is used to analyze any significant effects on translucency and flexural strength. Then, any significant difference in the translucency and flexural strength between all pairs of materials was analyzed using Bonferroni-corrected Student's t-test (α = 0.05). The high translucency sintering protocol significantly decreased biaxial strength in the Prime translucent and dentine layer, Prime esthetic translucent, and gradient layer. RTP00 was significantly reduced in the Prime gradient and Prime esthetic gradient layer when sintered with a high translucency protocol. The lowest ΔRTP00 was observed in the Prime dentine layer, while the highest ΔRTP00 was observed in the Prime esthetic dentin layer. High translucency protocol significantly lowers the biaxial flexural strength of both multilayered materials, but the alteration in translucency is within clinically acceptable thresholds (TAT00 = 2.62).

Liquid State Sintering enhances Consolidation in Basalt-rich Lunar Regolith

Constructing habitable load-bearing structures on lunar and martian surfaces presents unique challenges, such as the ability to sustain extreme thermal fluctuations and frequent dust storms. A promising paradigm for effecting construction is via in situ resource utilization (ISRU), combined with sintering, wherein locally available regolith is consolidated at high temperatures to make load-bearing structures. This work investigates one route for effecting sintering via intermediate melting of a constituent mineral, termed liquid state sintering, to enhance consolidation in lunar regolith simulants. We work primarily with lunar highland simulant (LHS-1), with supporting comparative investigations of lunar mare dust simulant (LMS-1) and martian global simulant (MGS-1). We first establish a liquid-state sintering protocol above the melting point of the constituent basalt using a combination of differential scanning calorimetry (DSC) and post-consolidation Scanning electron microscopy (SEM). A numerical lattice-based model is used to explain several of the experimental observations, including complex pore-crack interactions in the consolidated bricks, potential strength anisotropy due to shrinkage, resulting crack patterns, and derive an exponential relation between strength and porosity.

Effect of low-temperature degradation and sintering protocols on the color of monolithic zirconia crowns with different yttria contents.

This study investigated the effects of low-temperature degradation (LTD) on the L*, a*, and b* values of highly translucent zirconia crowns. Four types of zirconia disks with different yttria contents (IPS e.max ZirCAD LT, IPS e.max ZirCAD MT, IPS e.max ZirCAD MT Multi, IPS e.max ZirCAD Prime, Ivoclar) and two shades (A2 and BL) were used. A crown was manufactured using four types of zirconia and LTD treated. Color measurements were performed, and the color difference (ΔE00) before and after LTD was calculated. The microstructure was determined through X-ray fluorescence and X-ray diffractometry. Highly translucent zirconia crowns showed greater changes in the a* and b* values than in the L* value after LTD, regardless of the shade. The Multi2 crowns exhibited a discernible color change due to the LTD treatment. The X-ray fluorescence results did not reveal any apparent change in the microstructure between sintering programs for all zirconia specimens.

Gas‐Separating Metal‐Organic Framework Membrane Films on Large‐Area 3D‐Printed Tubular Ceramic Scaffolds

Polycrystalline metal‐organic framework (MOF) membrane films prepared on ceramic supports can separate gases with high energy efficiency. They generally exhibit very high permeance and selectivity but suffer from cost issues through the required ceramic supports. Increasing the area and reducing the ceramic component to a minimum can be a strategy to enabling neat membranes of MOFs. In a rapid prototyping approach using 3D‐printed porous scaffolds with a double‐helical channel geometry, an increased active membrane area‐to‐volume ratio is shown. Following stereolithographic printing and debinding of a ceramic slurry, an adapted sintering protocol is employed to sinter commercially available alumina slurries into porous scaffolds. The 3D‐printed scaffolds are optimized at a porosity of 40%, with satisfying mechanical stability. Furthermore, synthetic procedures yielding omnidirectional, homogeneous coatings on the outside and inside of the tubular scaffolds are developed. Membrane films of zeolitic imidazolate framework 8 and Hong Kong University of Science and Technology 1 covering a huge 50 cm2 membrane area are produced in this way by applying a counter‐diffusion methodology. Gas‐separation performance is evaluated for H2, CO2, N2, and CH4, in single‐gas measurements and on their binary‐gas mixtures.

Effect of two sintering protocols on translucency and flexural strength of different monolithic zirconia materials: An In vitro study

Effect of two sintering protocols on translucency and flexural strength of different monolithic zirconia materials: An In vitro study

Lead-free KNNLT piezoceramic multilayer actuators with Ni electrodes cofired under low oxygen partial pressure

The fabrication of piezoelectric multilayer actuators (MLA) with lead-free piezoceramic materials and excellent performance represents a great challenge in the process of replacing the current family of lead-based actuators. Sintering under low pO2 allows co-firing with base metal electrodes, which is an important step towards competitive multilayer actuator fabrication technologies. We prepared sodium potassium niobate (KNNLT) piezoelectric multilayer actuators with Ni electrodes by sintering at low pO2 of 10−11 atm at 950 °C, followed by reoxidation at 850 °C in 10−6 atm. We demonstrate the impact of the sintering protocol, i.e., sintering temperature Ts and pO2, on the phase composition and continuity of Ni electrodes, and on the actuator performance. We discuss the subtle interplay between sintering conditions, microstructure, reoxidation kinetics and piezoelectric performance. The Ni-MLA exhibits a unipolar strain of 0.74 ‰ at 3 kV/mm, a normalized strain coefficient d33* = 247 p.m./V and a loss of tanδ = 0.041.

Effect of different sintering protocols on the fracture strength of 3-unit monolithic gradient zirconia fixed partial dentures: An in vitro study

Strength-gradient zirconia combining 3 zirconia formulations with different flexural strengths has been reported to have outstanding mechanical properties. However, data concerning the effect of different sintering protocols on the fracture strength of 3-unit monolithic gradient zirconia fixed partial dentures (FPDs) are sparse. The purpose of this in vitro study was to test the effect of different sintering protocols on the fracture strength of 3-unit monolithic gradient zirconia FPDs. Two custom-made stainless-steel master dies were designed to replicate a mandibular right second premolar and second molar prepared to receive a 3-unit monolithic zirconia FPD. Thirty monolithic zirconia FPDs were milled from gradient zirconia blanks and allocated to 3 groups (n=10) according to the sintering protocols: high-speed sintering, speed sintering, and conventional sintering. The FPDs were cemented onto the corresponding dies with traditional glass ionomer cement. All FPDs were cyclic loaded (600 000 cycles/49N/1.7Hz) in a mastication simulator. Fracture load measurements for each FPD were determined by using a universal testing machine. Scanning electron microscopy (SEM) at ×80 magnification was used to examine a fractured FPD from each group. A representative specimen from each group was examined with SEM at ×30 000 magnification to determine the grain size. One-way ANOVA, pair-wise Tukey honestly significant difference (HSD), and Pearson correlation tests were used for statistical analysis of the data (α=.05). The high-speed sintered FPDs recorded the highest statistically significant fracture load mean ±standard deviation value (2526 ±300N), followed by the speed sintered FPDs (2136 ±127N), while the lowest statistically significant fracture load mean value was recorded with the conventionally sintered FPDs (1361 ±181N) (P<.001). In addition, the mean ±standard deviation grain size values were 488 ±272nm for the high-speed sintered specimen, 578 ±409nm for the speed sintered specimen, and 832 ±551nm for the conventionally sintered specimen (P<.001). A significant negative correlation was found between fracture strength and grain size among the 3 groups. The fracture strength of 3-unit monolithic gradient zirconia FPDs sintered by using a high-speed protocol was significantly higher than that of speed and conventionally sintered FPDs (P<.001). The high-speed sintering protocol reduced the mean grain size of gradient zirconia FPDs compared with that of both speed and conventional sintering protocols.

Influence of Microstructure on the Material Properties of LLZO Ceramics Derived by Impedance Spectroscopy and Brick Layer Model Analysis.

Variants of garnet-type Li7La3Zr2O12 are being intensively studied as separator materials in solid-state battery research. The material-specific transport properties, such as bulk and grain boundary conductivity, are of prime interest and are mostly investigated by impedance spectroscopy. Data evaluation is usually based on the one-dimensional (1D) brick layer model, which assumes a homogeneous microstructure of identical grains. Real samples show microstructural inhomogeneities in grain size and porosity due to the complex behavior of grain growth in garnets that is very sensitive to the sintering protocol. However, the true microstructure is often omitted in impedance data analysis, hindering the interlaboratory reproducibility and comparability of results reported in the literature. Here, we use a combinatorial approach of structural analysis and three-dimensional (3D) transport modeling to explore the effects of microstructure on the derived material-specific properties of garnet-type ceramics. For this purpose, Al-doped Li7La3Zr2O12 pellets with different microstructures are fabricated and electrochemically characterized. A machine learning-assisted image segmentation approach is used for statistical analysis and quantification of the microstructural changes during sintering. A detailed analysis of transport through statistically modeled twin microstructures demonstrates that the transport parameters derived from a 1D brick layer model approach show uncertainties up to 150%, only due to variations in grain size. These uncertainties can be even larger in the presence of porosity. This study helps to better understand the role of the microstructure of polycrystalline electroceramics and its influence on experimental results.

Templated grain growth in rapid sintered 3D-printed alumina ceramics

Textured microstructures in ceramics have gained interest due to their beneficial effect on structural and functional properties. For instance, morphologically textured grains in alumina-based ceramics can increase their damage tolerance. Texturing of alumina ceramics may be achieved through templated grain growth (TGG) occurring during sintering at high temperatures with prolonged dwell times (hours) and may be further enhanced by the presence of a liquid phase. In this study, we demonstrate the feasibility of texturing 3D-printed alumina ceramics within minutes by combining rapid heating (∼450 °C/min) and short dwell times (<20 min). The effect of sintering temperature and dwell time is investigated on samples with and without liquid phase. Experimental findings show highest texture degree for samples rapid sintered at 1600 °C for 16 min, opening the path for tailoring the microstructure of 3D-printed ceramics using pressure-less rapid sintering protocols.

Effect of superspeed sintering on translucency, opalescence, microstructure, and phase fraction of multilayered 4 mol% yttria-stabilized tetragonal zirconia polycrystal and 6 mol% yttria-stabilized partially stabilized zirconia ceramics

Statement of problemThe optical properties of recently developed multilayer zirconia have mainly been studied for the effects of conventional sintering and speed sintering but not as much for the effect of superspeed sintering. As superspeed sintering protocols typically require a higher sintering temperature and higher heating and cooling rates than speed- and conventional sintering protocols, the optical properties of superspeed sintered zirconia may be affected differently. PurposeThe purpose of this in vitro study was to investigate the effect of superspeed sintering on the optical properties, microstructure, and phase fraction of multilayered 4 mol% yttria-stabilized (4Y-) and 6 mol% yttria-stabilized (6Y-) zirconia. Material and methodsMultilayered 4Y- and 6Y-zirconia were sectioned. After conventional and superspeed sintering, the translucency parameter (TP), and opalescence parameter (OP) were measured with a spectrophotometer (n=10). To obtain the grain sizes from the field emission scanning electron microscopy (FE-SEM) images for each layer (n=2), more than 500 (6Y-zirconia) and 800 grains (4Y-zirconia) were measured by linear intercept methods. The phase fractions were obtained through X-ray diffraction (XRD) analysis by using the Rietveld method (n=1). The results were analyzed by 3-way ANOVA and post hoc Tukey honest significant difference tests (TP and OP) and by 3-way ANOVA and post hoc Scheffé tests (grain size) (α=.05). ResultsNo layers exhibited a significant difference in TP after superspeed sintering, except the dentin layer (DL) and transition layer 2 (T2) of 4Y- and 6Y-zirconia, respectively. The TP increased (P<.05) in DL for superspeed sintered 4Y-zirconia and decreased (P<.05) in T2 for the superspeed sintered 6Y-zirconia. However, the difference in TP by superspeed sintering was lower than the perceptibility thresholds of 50:50%. The OP decreased (P<.05) in the DL and T2 of 4Y-zirconia after superspeed sintering. For 6Y-zirconia, the OP decreased (P<.05) in all layers except for the transition layer 1 (T1) after superspeed sintering. However, the difference in OP values was minimal, with only a 1.1 difference observed for Zolid Gen-X (4Y) and a range of 1.22 to 1.62 for Katana UTML (6Y) when using superspeed sintering. No significant change was found in the grain size after superspeed sintering of either zirconia. Regardless of the sintering speed, the average grain size of the 6Y-zirconia (conventional: 2.09 to 2.21 μm; superspeed: 2.11 to 2.20 μm) was larger than that of the 4Y-zirconia (conventional: 0.50 to 0.52 μm; superspeed: 0.52 to 0.54 μm). Owing to superspeed sintering, the metastable tetragonal (T′) phase content increased while the tetragonal (T) phase decreased in 4Y-zirconia; in 6Y-zirconia, the cubic (C) phase content increased, while the T′-phase content decreased. ConclusionsSuperspeed sintering did not result in any clinically significant changes in the translucency and opalescence of 4Y- or 6Y-zirconia.

Optical effect of rapid sintering protocols on different types of zirconia

Statement of problemRapid sintering protocols are available for the fabrication of zirconia restorations, but whether rapid sintering influences color or translucency is unclear. PurposeThe purpose of this in vitro study was to investigate the effect of different rapid sintering protocols on the color and translucency of cubic and tetragonal zirconias. Material and methodsSixty disk-shaped specimens of 1-mm-thick cubic (DD CubeX2) and tetragonal (DD Bio ZX2) zirconia were investigated. Specimens of each type of zirconia were divided into three groups: conventional, speed, and superspeed sintering protocols. The conventional group of each zirconia type served as the control for calculating color differences. Translucency for each group was assessed by the translucency parameter and contrast ratio. Two-way analysis of variance was used for statistical analysis of the data (α=.05). ResultsThe translucency of cubic and tetragonal zirconia decreased after speed and superspeed sintering (P<.001). Superspeed sintering resulted in a greater color change than speed sintering (P<.001). ConclusionsRapid sintering protocols produced a significant effect on the color and translucency of cubic and tetragonal zirconias.

Investigation of Chemical and Thermal Stability of Li7−xLa3Zr2−xTaxO12 Garnet Type Solid‐State Electrolyte to Assemble Self‐Standing Li‐based All Solid‐State Battery

All solid‐state batteries (ASSB) are the next generation of safe and high‐energy‐density energy storage technology. Their development is currently impeded by the stability issues of solid‐state electrolyte (SSE) limiting the creation of interfaces of quality high enough to ensure efficient transfer of charges. The garnet Li7−xLa3Zr2−xTaxO12 (LLZO:Ta) is one of the most appealing oxide‐based SSE but its high sensitivity to moist air engenders difficulties in designing process to densify and assemble components of the ASSB. Based on a careful investigation of LLZO:Ta thermal and chemical stability, a heat treatment is designed and shown to fully reverse the protonation process. The investigation of spark plasma sintering protocols confirms that pretreated LLZO:Ta can be densified at a temperature as low as 850 °C or with a short duration (few seconds) at 900 °C. The characterization of obtained ceramics shows conductivities close to the bulk properties and confirms the absence of influence of grain boundaries. The study of composite electrodes shows that LLZO:Ta is suitable to act both as SSE separator and ionic percolator in positive electrode, the selection of active material remains the main issue to target self‐standing Li‐based ASSB.

The effects of heating rate and sintering time on the biaxial flexural strength of monolithic zirconia ceramics.

The strength of zirconia ceramic materials used in restorations is dependent upon sintering. Varying sintering protocols may affect the biaxial flexural strength of zirconia materials. This invitro study was conducted to investigate the effects of sintering parameters on the biaxial flexural strength of monolithic zirconia. Two different monoblock zirconia ceramics were used. Following coloration, samples of both types of ceramics were divided into groups according to whether or not biaxial flexural strength testing was performed directly after sintering or following thermocycling. Biaxial flexural strength data was analysed with a Shapiro Wilk normality test, followed by 1-way ANOVA, Tukey post hoc tests for inter-group comparisons, and paired samples t-tests for intra-group comparisons. Asignificant difference was found between the biaxial flexural strengths of Zircon X and Upcera ceramics before thermocycling (p<0.05). In both Zircon X and Upcera ceramic groups, the thermocycling process created a significant difference in the biaxial flexural strength values of the ceramic samples in Group 6 (p<0.05) which had the slowest heating rate and longest holding time. The zirconia ceramics have higher BFS at higher heating rates either before or after thermocycling. The holding time has significant effects on thermocycling and flexural strength. The zirconia achieved its optimum strength when it sintered at longer time regardless of heating rates.

Speed-sintering and the mechanical properties of 3-5mol% Y2O3-stabilized zirconias.

Ever faster workflows for the fabrication of all-ceramic restorations are of high economic interest. For that purpose, sintering protocols have been optimized for use in modern sintering furnaces, the so-called speed-sintering. However, conventional furnaces are still the most widely used equipment to sinter zirconia restorations. In this in-vitro study, we evaluated the feasibility of a speed-sintering protocol using a conventional sintering furnace to sinter different dental zirconias (stabilized with 3mol% up to 5.4mol% Y2O3) in comparison to a conventional sintering program. The properties evaluated were Young's modulus, Poisson's ratio, density, biaxial flexural strength, and fracture toughness. We show here that despite differences being dependent on material, the physical and mechanical properties of speed-sintered zirconia are comparable to those obtained by the conventional sintering.

Comparison of Regular and Speed Sintering on Low-Temperature Degradation and Fatigue Resistance of Translucent Zirconia Crowns for Implants: An In Vitro Study.

Although there are a few studies which compare fast and slow sintering in normal zirconia crowns, it is essential to compare the cracks and load-bearing capacity in zirconia screw-retained implant crowns between regular and speed sintering protocols. This research aimed to compare the surface structure, cracks, and load-bearing capacity in zirconia screw-retained implant crowns between regular sintering (RS) and speed sintering (SS) protocol with and without cyclic loading (fatigue). A total of 60 screw-retained crowns were fabricated from zirconia (Katana STML Block) by the CAD/CAM system. Then, 30 crowns were subjected to the RS protocol and 30 crowns were subjected to the SS protocol. Cyclic loading was done in half zirconia crowns (15 crowns in each group) using a chewing simulator CS-4.8/CS-4.4 at room temperature. The loading force was applied on the middle of the crowns by a metal stylus underwater at room temperature with a chewing simulator at an axial 50 N load for 240,000 cycles and lateral movement at 2 mm. Scanning electron microscopy was done to study the surface of the crowns and the cracks in the crowns of the regular and speed sintering protocols, with and without fatigue. For the speed sintering group, the surface looks more uniform, and the crack lines are present at a short distance compared to regular sintering. The sintering protocol with a larger Weibull module and durability increases the reliability. It showed that the Speed group showed the maximum fracture load, followed by the regular, speed fatigue, and regular fatigue groups. The fracture load in various groups showed significant differences. It was found that the speed group showed the maximum fracture load followed by the regular, speed fatigue, and regular fatigue. The crack lines ran from occlusal to bottoms (gingiva) and the arrest lines were perpendicular to the crack propagations.

Effect of sintering time on the marginal and internal fit of monolithic zirconia crowns containing 3–4 mol% Y2O3

BackgroundShort-term sintering may offer advantages including saving time and energy but there is limited evidence on the effect that altering sintering time has on the accuracy of monolithic zirconia crowns. The purpose of this in vitro study was to investigate the effect of shortened sintering time on the marginal and internal fit of 3Y-TZP and 4Y-TZP monolithic crowns.MethodsSixty monolithic zirconia crowns were fabricated for the maxillary first molar tooth on the prefabricated implant abutment. Groups were created according to the material composition: 3Y-TZP Generation 1, 3Y-TZP Generation 2 and 4Y-TZP. Two different sintering protocols were performed: same final sintering temperature (1500 °C) and various rates of heating (10 °C/min and 40 °C/min), cooling down speed (− 10 °C/min and − 40 °C/min), holding time (45 and 120 minutes), and total sintering time (approximately 2 and 7 hours, respectively). The marginal and internal fit of the crowns were determined using the silicone replica technique. Comparisons between groups were analyzed using two-way ANOVA. Pairwise multiple comparisons were performed using t-test (p < 0.05).ResultsThe mean marginal gap values of 4Y-TZP zirconia revealed statistically significant increase for the short-term sintering protocol (p < 0.0001), while no difference was observed between the sintering protocols for the mean marginal gap values of 3Y-TZP groups. Although all groups showed clinically acceptable gap values, altering the sintering time had an effect on marginal fit of the crowns manufactured from 4Y-TZP zirconia.ConclusionsShortening the sintering time may lead to differences within clinically acceptable limits. The manufacturer’s recommendations according to material composition should be implemented with care.

A technique to modify the photoluminescence intensity of β-Ga2O3 polycrystals using an electric field during sintering

Beta gallium trioxide (β-Ga2O3) is an attractive wide bandgap oxide that exhibits photoluminescent emission in the ultraviolet and blue/green regions. In the present study, we describe the tuning and enhancement of photoluminescent emission in the blue/green region by applying an instantaneous electric field during the sintering of a β-Ga2O3 green compact. Blue/green emission at around 480 nm increases by a factor of approximately 16 in β-Ga2O3 polycrystal prepared with the sintering protocol that a green compact was heated up to 1300 °C and an alternating current electric field (50 V/cm at 1000 Hz) was isothermally loaded. Considering that the enhancement occurs at the cathode side under a direct current electric field, the enhanced blue/green photoluminescence is likely due to an increase in the number of oxygen vacancies.

High-strength lithography-based additive manufacturing of ceramic components with rapid sintering

Additive manufacturing technology enables the fabrication of technical ceramics and multi-materials with unprecedented geometrical accuracy and complexity, opening the path to new functionalities for engineering applications. A crucial step to consolidate 3D-printed ceramic parts is “sintering”, a time and energy (temperature) intensive densification process. Here we present a strategy for rapid sintering (∼ 300–450 °C/min) of lithography-based additively manufactured alumina ceramics enabling consolidation of ceramic components of complex shapes within minutes. Highly dense, fine-grained microstructures were achieved by controlling densification and limiting grain growth through rapid radiation heat transfer. The high mechanical strength and toughness measured in additively manufactured alumina (∼ 810 MPa and ∼ 4.3 MPa m 1/2 ) sintered at 1600 °C within 2 min was superior to that of conventionally sintered reference parts. This study opens the path for rapid sintering of complex shaped ceramic architectures of high density with tailored microstructure and properties. • 3D-printed ceramics with complex geometry can be sintered within minutes. • Rapid radiation using a customized Spark Plasma Sintering system promotes densification. • Controlling the dwell sintering time allows tailoring of grain size in refined microstructures. • Dense and exceptionally high strength 3D-printed alumina were achieved. • Our sintering protocol may be applied to other 3D printed ceramic materials.