Vat photopolymerization 3D printing of ceramic cores: Advances, challenges, and prospects

To meet the evolving demands of aeroengine development, the structural and performance requirements for ceramic cores have become increasingly stringent. Vat photopolymerization 3D printing, owing to its moldless, flexible manufacturing, and other advantages, demonstrates significant potential in the preparation of ceramic cores with intricate structures. However, its practical application still faces multiple challenges, including layered structures and property anisotropy, defects such as cracks and collapse during printing and sintering, forming inaccuracies, and difficulties in controlling surface roughness. Recent advances have focused on optimizing slurry formulation and rheology, improving curing behavior, introducing auxiliary powders and additives, tailoring forming parameters, and optimizing the sintering process. Nevertheless, effectively suppressing lamellar defects, achieving superior dimensional accuracy, and maintaining high surface quality in complex structures remain the core scientific and technical issues to be solved. Future research should concentrate on refining curing mechanisms, advancing powder design and organic system optimization, and regulating the coupled processes of forming, debinding, and sintering to accelerate the application of VPP 3D printed ceramic cores in aerospace manufacturing.