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Materials
Volume 18
Issue 11
10.3390/ma18112445
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Review

Additive Manufacturing of Alumina-Based Ceramic Structures by Vat Photopolymerization: A Review of Strategies for Improving Shaping Accuracy and Properties

by
Jia-Jun Zhao
,
Yun-Zhuo Zhang
,
Jia-Hao Li
,
Zi-Heng Wang
,
Wei-Jian Miao
,
Fan-Bin Wu
,
Shu-Qi Wang
* and
Jia-Hu Ouyang
*
School of Materials Science and Engineering, Harbin Institute of Technology, Harbin 150001, China
*
Authors to whom correspondence should be addressed.
Materials 2025, 18(11), 2445; https://doi.org/10.3390/ma18112445
Submission received: 1 May 2025 / Revised: 19 May 2025 / Accepted: 22 May 2025 / Published: 23 May 2025
(This article belongs to the Special Issue Multiphase Systems with Polymeric Matrices: Polymer Blends and Composites (3rd Edition))
Versions Notes

Abstract

Alumina is a polycrystalline oxide ceramic with different structures. Currently, α-alumina with a hexagonal close-packed stacking structure is mainly used for a variety of industrial applications. Alumina-based ceramics and composites have been widely used in various fields due to their excellent hardness, strength, creep resistance and good biocompatibility. However, it is difficult for Al2O3 ceramic components based on traditional preparation methods to meet the increasing industrial requirements, especially for applications such as precise multi-walled complex structures. Al2O3 ceramic additive manufacturing by vat photopolymerization 3D printing stands out owing to its ability to produce complex structures and tailored shaping accuracy/properties. The vat photopolymerization 3D printing of Al2O3 ceramics requires multiple steps including slurry preparation, photopolymerization shaping, debinding and sintering. Therefore, many efforts mainly focus on the strategies of optimizing the ceramic slurry formulation and the debinding/sintering process. This paper provides a scoping review to present optimization strategies for the above aspects of vat photopolymerization 3D printing, which creates a strong reference for researchers to improve the accuracy and properties of alumina parts. Finally, this review also states the main applications of Al2O3 ceramic components based on vat photopolymerization, and highlights the opportunities and challenges associated with this technology in the future. It is beneficial to understanding the future trends and policy directions of advanced manufacturing industry.
Keywords: vat photopolymerization; Al2O3; debinding; sintering; additive manufacturing; stereolithography; digital light processing vat photopolymerization; Al2O3; debinding; sintering; additive manufacturing; stereolithography; digital light processing

Share and Cite

MDPI and ACS Style

Zhao, J.-J.; Zhang, Y.-Z.; Li, J.-H.; Wang, Z.-H.; Miao, W.-J.; Wu, F.-B.; Wang, S.-Q.; Ouyang, J.-H. Additive Manufacturing of Alumina-Based Ceramic Structures by Vat Photopolymerization: A Review of Strategies for Improving Shaping Accuracy and Properties. Materials 2025, 18, 2445. https://doi.org/10.3390/ma18112445

AMA Style

Zhao J-J, Zhang Y-Z, Li J-H, Wang Z-H, Miao W-J, Wu F-B, Wang S-Q, Ouyang J-H. Additive Manufacturing of Alumina-Based Ceramic Structures by Vat Photopolymerization: A Review of Strategies for Improving Shaping Accuracy and Properties. Materials. 2025; 18(11):2445. https://doi.org/10.3390/ma18112445

Chicago/Turabian Style

Zhao, Jia-Jun, Yun-Zhuo Zhang, Jia-Hao Li, Zi-Heng Wang, Wei-Jian Miao, Fan-Bin Wu, Shu-Qi Wang, and Jia-Hu Ouyang. 2025. "Additive Manufacturing of Alumina-Based Ceramic Structures by Vat Photopolymerization: A Review of Strategies for Improving Shaping Accuracy and Properties" Materials 18, no. 11: 2445. https://doi.org/10.3390/ma18112445

APA Style

Zhao, J.-J., Zhang, Y.-Z., Li, J.-H., Wang, Z.-H., Miao, W.-J., Wu, F.-B., Wang, S.-Q., & Ouyang, J.-H. (2025). Additive Manufacturing of Alumina-Based Ceramic Structures by Vat Photopolymerization: A Review of Strategies for Improving Shaping Accuracy and Properties. Materials, 18(11), 2445. https://doi.org/10.3390/ma18112445

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