Defect control in digital light processing of high-solid-loading ceramic core

In order to investigate the defect control mechanism and the optimal cure parameter window, high-solid-loading ceramic-core green-body samples were fabricated by digital light processing (DLP) with different cure parameters. The defects appearing on the sample surface were observed. The causes of the wrong-cured zone and the propagation mechanism of UV light in the ceramic suspension were explained. The effect of different cure parameters on the printed structure of single- and multi-layer samples was investigated. The results showed that the single-layer sample had excellent cure accuracy, and the step effect was significantly reduced in the multi-layer samples at the exposure energy density of 6–8 mW/cm 2 and the exposure time of 2.5–3.5s. Based on the systematic observation of the sample structure, a system for prediction, evaluation, and process optimization of defects in ceramic-core green-body samples was proposed.