Stereolithography 3D printing of 3Y-TZP ceramics through synergistic optimization of solid content and sintering

Stereolithography 3D printing enables the production of intricate ceramics part with high precision and design flexibility from photosensitive ceramic slurries. Herein, we propose an approach using different dispersants (BYK-111 and KOS-110) and varying solid contents (40 vol%, 45 vol% and 50 vol%) to achieve stable flowability and improved curing layer thickness. The influence of debinding in air and argon atmospheres was investigated. Notably, debinding under an argon atmosphere not only prevented cracks but also enhanced the densification of the specimens. The optimal sintered 3Y-TZP ceramic specimen, sintered at 1500 °C, exhibited a shrinkage of 24 % in the XY-direction and 31 % along Z-direction, with a relative density of 98.09 %, weight loss of 18.50 % and open porosity of 0.24 %. Additionally, this sintered specimen demonstrated promising bending strength (784.8 MPa), and hardness of (18.06 GPa), ensuring dense printed parts with high-temperature durability. Our findings shed light on the key factors affecting the fabrication of high-density, high-performance ceramic parts with enhanced structural integrity and thermal stability.