Digital light processing of complex-shaped 3D-zircon (ZrSiO4) ceramic components from a photocurable polysiloxane/ZrO2 slurry.

Explorations in the stereolithography fabricated polymer-derived ceramics are still far from maturity. Herein, a novel preceramic slurry, which consists of a photocurable epoxy-acrylic siloxane and particle-size gradated ZrO 2 fillers, was digital light processing shaped into 3D preceramic precursors. By taking advantage of the high reactivity of in-situ formed silica from the polysiloxane, 3D-zircon product can be synthesized through the sintering reaction between the polysiloxane and ZrO 2 particles in the precursor at a low temperature. During the sintering process, ZrSiO 4 phase starts to appear at the temperature of 1200 °C. A proper particle-size distribution of the ZrO 2 filler, 20 wt% of micropartciles and 4 wt% of nanoparticles, not only endowed the ceramic slurry with a low viscosity but also increase the purity of the zircon products. Besides, the addition of sintering aid NaF can promote the sintering reaction between the polysiloxane and ZrO 2 particles while increase the crystalize degree of the 3D-zircon products. [ABSTRACT FROM AUTHOR]