Effect of sintering temperature on feature resolution and flexural strength of ceramics fabricated through vat photopolymerization additive manufacturing

Bezek, Lindsey Bernadette; Lee, Kwan-Soo

doi:10.1108/rpj-04-2024-0166

Effect of sintering temperature on feature resolution and flexural strength of ceramics fabricated through vat photopolymerization additive manufacturing

Journal Article · Wed Sep 11 00:00:00 EDT 2024 · Rapid Prototyping Journal

DOI:https://doi.org/10.1108/rpj-04-2024-0166· OSTI ID:2447576

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Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)

Although ceramic additive manufacturing (AM) could be used to fabricate complex, high-resolution parts for diverse, functional applications, one ongoing challenge is optimizing the post-process, particularly sintering, conditions to consistently produce geometrically accurate and mechanically robust parts. This study aims to investigate how sintering temperature affects feature resolution and flexural properties of silica-based parts formed by vat photopolymerization (VPP) AM. Test artifacts were designed to evaluate features of different sizes, shapes and orientations, and three-point bend specimens printed in multiple orientations were used to evaluate mechanical properties. Sintering temperatures were varied between 1000°C and 1300°C. Deviations from designed dimensions often increased with higher sintering temperatures and/or larger features. Higher sintering temperatures yielded parts with higher strength and lower strain at break. Many features exhibited defects, often dependent on geometry and sintering temperature, highlighting the need for further analysis of debinding and sintering parameters. To the best of the authors’ knowledge, this is the first time test artifacts have been designed for ceramic VPP. This work also offers insights into the effect of sintering temperature and print orientation on flexural properties. These results provide design guidelines for a particular material, while the methodology outlined for assessing feature resolution and flexural strength is broadly applicable to other ceramics, enabling more predictable part performance when considering the future design and manufacture of complex ceramic parts.

View Accepted Manuscript (DOE)

Research Organization:: Los Alamos National Laboratory (LANL), Los Alamos, NM (United States)

Sponsoring Organization:: USDOE Laboratory Directed Research and Development (LDRD) Program; USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: 89233218CNA000001

OSTI ID:: 2447576

Report Number(s):: LA-UR--23-30795

Journal Information:: Rapid Prototyping Journal, Journal Name: Rapid Prototyping Journal Journal Issue: 11 Vol. 30; ISSN 1355-2546

Publisher:: Emerald Group PublishingCopyright Statement

Country of Publication:: United States

Language:: English

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36 MATERIALS SCIENCE
Additive manufacturing
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Silica-based ceramics
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Effect of sintering temperature on feature resolution and flexural strength of ceramics fabricated through vat photopolymerization additive manufacturing

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