Optimization of Resin Composition for Zirconia Ceramic Digital Light Processing Additive Manufacturing

In ceramic digital light processing (DLP) additive manufacturing, the photosensitive resin, which acts as a carrier for ceramic particles, must exhibit suitable curing performance, curing strength, and viscosity. This ensures both the bonding strength of the fabricated ceramic parts and the dimensional accuracy of the ceramic green body. In this study, various photosensitive resin monomers were investigated in depth to formulate resins containing monofunctional, bifunctional, and multifunctional groups. Their rheological and curing properties were analyzed theoretically and experimentally. Different resin slurry systems were prepared and printed using DLP technology, and their mechanical properties were tested and compared. The effect of photoinitiator content on the curing behavior of the resin was examined, and the optimal photoinitiator concentration was identified. Based on the optimized resin, a zirconia ceramic slurry with 56 vol% solid content was prepared. After DLP printing, debinding, and sintering, dense zirconia ceramic samples with a relatively uniform grain structure were obtained, exhibiting a bending strength of 766.85 MPa. These results significantly expand the potential applications for zirconia ceramic components with complex geometries.