Ceramic green bodies can be created using stereolithography methods where a ceramic suspension consisting of 0.40–0.55 volume fraction ceramic powder is dispersed within an ultraviolet‐curable solution. Three ceramic materials were investigated: silica for investment casting purposes, and alumina and silicon nitride for structural parts. After mixing the powders in the curable solution, the ceramic suspension is photocured, layer by layer, fabricating a three‐dimensional ceramic green body. Subsequent binder removal results in a sintered ceramic part. Three‐dimensional objects have been fabricated from a 0.50 volume fraction silica suspension.
Porous ceramic bodies with interconnected pore channels were fabricated by a novel freeze casting technique using camphene‐based slurries. The pore channels are surrounded by almost fully dense walls and have nearly circular cross‐sections. The pore volume fraction and the channel size were controllable by the solid content in the slurry. The channels are replicas of entangled dendrites of frozen camphene, which sublimed during the freeze‐drying process. This porous structure with entangled pore channels is considered potentially useful in many applications such as implantable bone scaffolds.
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