A systematic insight into the DLP process of additive manufactured Al₂O₃ceramic green body

In vat photopolymerization (VPP) additive manufacturing of ceramics, the stereolithographic process is pivotal for the manufacturing of the green body and its debinding and sintering process, thereby affecting the performance of ceramic components. This study systematically investigates the effects of key process parameters (slicing thickness, exposure time, and building direction) on the mechanical properties and microstructure of Al₂O₃ green bodies fabricated using Digital Light Processing (DLP). The results indicate that excessive layer thickness leads to inadequate curing and interlayer cracking, while using thinner layers does not significantly improve mechanical strength but instead prolongs the manufacturing cycle time. Furthermore, the exposure time has been shown to directly influence the curing degree of the resin matrix, with longer times enhancing strength through improved polymerization. Exposure time directly affects the curing degree of the resin matrix, with longer exposure times enhancing strength through improved polymerization. The building direction of the specimen is also of critical importance. Specimens built along the Y-direction exhibited the highest flexural strength due to the loading direction relative to the interlayer bonds. The fabrication of complex-shaped Al₂O₃ green bodies was achieved using the optimized parameters, demonstrating the effectiveness of DLP for producing advanced ceramic components.