Advancements in DLP 3D printing: High strength alumina toughened zirconia ceramics for biomedical applications

Digital Light Processing (DLP) enables intricate ceramic part production from photosensitive ceramic slurry. While ZrO₂ and Al₂O₃ are commonly studied, their composites are underexplored despite diverse applications. This study investigates fabricating high-strength, fully dense alumina-toughened zirconia (ATZ) parts using a low-cost desktop DLP printer designed for polymer printing. Various ATZ-based ceramic slurries (30, 35, 42.5 vol%) with different binders and dispersants were prepared and evaluated for curing and rheological properties. Promising formulations underwent debinding and sintering, resulting in homogenous microstructures with a well-distributed blend of the two phases. For the doped samples, SEM analysis revealed a good distribution of dopants and elongated dopant grains infused at higher temperatures. The 35 vol% ATZ exhibited exceptional average flexural strength of 1321 MPa, surpassing previous DLP-fabricated composites. This suggests no need for increased solid loading content. The findings demonstrate the potential of DLP in producing high-performance ceramic parts with tailored properties.