Stereolithographic 3D Printing of Ceramics: Challenges and Opportunities for Structural Integrity

Abstract

This article reviews the current activities at the Montanuniversität Leoben on the design, processing, and characterization of 3D printed advanced ceramics using the lithography-based manufacturing technology. An overview of the challenges and the opportunities offered to improve the mechanical properties of printing ceramics is given. Their brittle failure is analyzed within the framework of linear elastic fracture mechanics, considering specific aspects of additive manufacturing. Several issues associated with the printing process are addressed, such as surface quality, geometry control, influence of printing directions, as well as the need to establish testing protocols for 3D printed parts. Based on the layer-by-layer capabilities of the stereolithographic process, bio-inspired material design concepts are discussed aiming to enhance the mechanical resistance of 3D-printed ceramics. By tailoring the layer architecture and microstructure of the parts, high strength and fracture resistance may be achieved.