Effect of photosensitive resins on the properties of vat photopolymerization‐based 3D printed alumina ceramics

Abstract Stereolithography‐based three‐dimensional printing fabricates objects through ultraviolet‐induced layerwise curing of photosensitive resins. This study systematically evaluated alumina ceramic parts fabricated using four distinct photosensitive resin systems. Key parameters including slurry viscosity, debinding/sintering behavior, microstructure, and mechanical properties were analyzed. Rheological tests revealed that ceramic slurries exhibited non‐Newtonian fluid characteristics, with viscosity significantly influenced by resin composition. Lumi React Hard & Detailed resin (resin A) produced the lowest slurry viscosity (0.386 Pa s). Directional sintering shrinkage rates for resin A demonstrated minimal anisotropy (9.5%‒16.5%). Post‐sintering characterization showed bulk density (1.82‒2.37 g/cm 3 ), porosity (40.3‒56.6 vol%), and bending strength (8.9‒14.6 MPa) variations across resin systems. Resins A and D (standard blends) yielded superior bending strength, correlating with optimized crosslinking and polymerization patterns observed in microstructural analysis. The findings establish resin selection as a critical determinant of ceramic part performance, providing technical guidance for stereolithography‐based ceramic manufacturing optimization. This work demonstrates the feasibility of tailoring material properties through photosensitive resin formulation engineering, expanding functional ceramic applications in additive manufacturing.