Effect of reactive diluent concentration on rheological and curing behavior of zirconia ceramic slurry for DLP printing

A series of photosensitive zirconia ceramic slurry with adjustable viscosity and cured depth have been presented for the construction of high-quality zirconia ceramic fabricated by digital light processing 3D printing. The rheological and curing behavior of the slurry can be flexibly optimized by tuning the reactive diluent concentration and category, since the change of dominant position of diluent on viscosity and the different curing mode. Monofunctional reactive diluent (HEA, hydroxyethyl acrylate) exhibits an enhanced dilution effect compared with that of bifunctional reactive diluent (HDDA, 1,6-hexamethylene diacrylate) due to the lower molecular mass of monofunctional diluent. As a result, the viscosity reaches lower than 2000 mPa·s when the concentration of both HEA and HDDA exceeds 50 wt.%. At the same time, the non-Newtonian properties of the slurry are also changed, which facilitates the printing process. However, excessive addition of diluent may generate more defects in ceramic green body. Consequently, the cured depth of zirconia slurry can reach 55 and 50 µm, respectively, at the curing time of 3 s while introducing the HEA or HDDA with the concentration below 70 wt.%, and the modified feedstock is promising for high-quality and low-defect zirconia ceramic components printing for biomedical applications.