Microstructures and Strengths of Metals and Ceramics made by Photopolymerbased Rapid Prototyping

Abstract

Metal and ceramic flexure specimens were fabricated using a photopolymer-based rapid prototyping technique. Photosensitive resins (inks) were produced by dispersing 50 - 55 vol% metal or ceramic powders in a photopolymer resin. Laminates 0.2" thick were built up by repeated application oflayers 3 - 10 mils thick followed by curing under a UV flood lamp with photomasks. The layered samples were thermally processed to remove the photopolymer binder and sintered to high density. Densities, microstructural characterization and flexure strengths are reported for silicon nitride, alumina, zirconia, stainless steel, and tungsten.