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Digital light processing 3D printing of ceramic materials: a review on basic concept, challenges, and applications

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Abstract

The accelerated growth of 3D printing technologies has revolutionized the potential of ceramic materials, offering unprecedented control over microstructures, saving labor cost, material, and process time. Stereolithography-based 3D printing has grown to fabricate advanced ceramics materials with the flexibility of mass production. 3D printing generally offers unprecedented versatility, fast-printing tangible design, custom freedom, and excellent laying accuracy. More specifically, ceramic materials offer unique mechanical properties to make them superior for various applications. A description of how digital light processing (DLP) 3D printing can play a pivotal role in fabricating oxide ceramics in terms of complex shape, material used, ceramic resin, debinding and sintering control, and theoretical background for accuracy and high resolution is presented along with their distinctive features. Within 2021–2026, the DLP printing market is expected to reach a GR of 5.9%. The current findings shed light on the potential of DLP printing open windows in ceramic materials, which is are very promising, a step forward to achieving sophisticated structures with great versatility and efficiency. This review article is devoted to ceramics and their oxides (Al2O3, ZrO2, and kaolin), non-oxides (Si3N3 and SiC), and Al2O3-reinforced ZrO2 composites, whose morphologies are elaborated in depth. Some key factors are prioritized, such as the ceramic resin, photoinitiator, monomers, and suspension, which may facilitate the scalability of the desired printing. A summary table concludes with the operating conditions, materials, and fundamental aspects of physiochemical and thermomechanical features in large-scale manufacturing.

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Funding

The author acknowledges Institute of Powder Metallurgy and Advanced Ceramics, School of Material Science and Engineering, University of Science and Technology Beijing, is grateful to the research chairs program for continued support.

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Authors and Affiliations

  1. Institute of Powder Metallurgy and Advanced Ceramics, School of Material Science and Engineering, University of Science and Technology Beijing, Beijing, 100083, China

    M. Irfan Hussain, Min Xia, XiaoNa Ren & Changchun Ge

  2. College of Mechanical and Electrical Engineering, Nanjing University of Aeronautics and Astronautics, Nanjing, China

    Muhammad Jamil

  3. Faculty of Mechanical Engineering, Opole University of Technology, 76 Proszkowska St, 45-758, Opole, Poland

    Munish Kumar Gupta

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  1. M. Irfan Hussain
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  2. Min Xia
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  6. Munish Kumar Gupta
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Hussain, M.I., Xia, M., Ren, X. et al. Digital light processing 3D printing of ceramic materials: a review on basic concept, challenges, and applications. Int J Adv Manuf Technol 130, 2241–2267 (2024). https://doi.org/10.1007/s00170-023-12847-3

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