Mechanical Challenges of 3D Printing Ceramics Using Digital Light Processing

Digital light processing (DLP) 3D printing can be used for manufacturing complex structures using a variety of materials, which would be nearly impossible using traditional manufacturing methods. Recent work at Sandia National Laboratories uses DLP technology for additive manufacturing of complex alumina structures, using photocurable resins loaded with micron or submicron alumina particles. These resins are printed using a DLP 3D printer to produce a “green part.” The work presented here will discuss the mechanical challenges associated with printing alumina using commercially available DLP and stereolithography 3D printers, including the design of a custom DLP 3D printer to address identified mechanical challenges, thereby leading to improved print versatility and quality.