Defect inhibition mechanism of 3D-printed ceramics via synergetic resin composition and debinding processing regulation

Producing ceramic parts by Vat Photopolymerization (VPP) additive manufacture with desired mechanical properties typically requires time-consuming debinding steps. This study aims at optimizing composition and processing parameters with the use of dibutyl phthalate (DBP) in the resin formulation and debinding in an argon atmosphere for dental zirconia-toughed alumina (ZTA). The method produces parts with fewer defects, and 67.7% higher flexural strength while increasing the debinding heating rate over 400% compared to standard formulations debinded in air. These improvements are attributed to pore formation at low temperatures and reduced heat release and gas evolution rates arising from use of the DBP and the inert atmosphere, respectively. While ZTA ceramics were studied, this method should be applicable to many ceramic systems with exciting possibilities for promoting the rapid development of VPP 3D-printed high-performance ceramics for various engineering applications. © 2024 The American Ceramic Society.