Preparation of high performance dense Al₂O₃ ceramics by digital light processing 3D printing technology

The incorporation of a significant amount of organic materials in the fabrication process of Al2O3 ceramics using digital light processing (DLP) 3D printing technology leads to a noticeable reduction in mechanical properties compared to those prepared using traditional methods. To enhance its mechanical performance of Al2O3 ceramics, the addition of MgO and MgO-Y2O3 sintering additives, along with a three-step curing method, has resulted in significant improvements. Al2O3 ceramics fabricated with the addition of MgO exhibited a flexural strength of 454.2 MPa, Vickers hardness of 20.24 GPa and apparent porosity of 0.15 %. Similarly, the addition of MgO-Y(2)O3 yielded Al2O3 ceramics with a flexural strength of 491.6 MPa, Vickers hardness of 20.91 GPa, and apparent porosity of 0.11 %. These values exceed the typical flexural strength of Al2O3 ceramics prepared using traditional methods. This research provides a fundamental basis for the production of high performance, dense, and complex shaped Al2O3 ceramics using DLP 3D printing technology.