Design of a Shaping System for Stereolithography with High Solid Loading Ceramic Suspensions

Abstract The challenges associated with ceramic stereolithography using high solid loading suspensions are related to the formation of ultrathin layers with high-viscosity suspensions and uneven green bodies, deriving from sedimentation problems. Furthermore, for a bottom-up projection system, the separating force must be focused. The digital light process system and bottom-up projection method have been used in this current work to create a ceramic green part. Our special design of a coating–storing–stirring recoating system tackles the problems relating to both ultrathin layers and sedimentation and it can also store the suspension to make the process more convenient. A stretch elastic separating film that diminishes the separating force and effectively reduces printing defects has also been designed. The strain forces in the improved coating process and stripping process were also analyzed. The green bodies were printed from three types of high solid loading ceramic suspensions (silica 60 vol%, alumina 60 vol%, and zirconia 52 vol%) with calculated parameters. Finally, the postprocessing of green parts was found to increase the density of ceramic components; these sintering results are presented.