Microstructural transformation and defect analysis in alumina ceramics components manufactured by stereolithography additive manufacturing technology

Abstract This study explores the stereolithography process for ceramic material, identifying defects and evaluating the characteristics of the fabricated parts. Each stage of the process (printing, cleaning, debinding, and sintering) is analyzed with a focus on material transformations and defect formation. Defects such as non-uniform material distribution, superficial damage from cleaning procedures, and residual organic compounds were identified in the printing, cleaning, and debinding stages. The sintering process revealed uneven consolidation, with varying degrees of particle bonding and residual porosity, highlighting the need for optimized thermal treatments. Surface roughness and dimensional analysis indicated the influence of printing orientation and thermal treatments on the final surface quality and shrinkage behaviour. Additionally, the study examined edge geometry and hardness, confirming that SLA technology can produce sharp edges and ceramic components with mechanical properties comparable to those of conventionally manufactured alumina. These findings underscore the importance of optimizing post-processing stages to minimize defects and improve part quality and performance of printed ceramic components for advanced applications.