Smaller feature size impairs densification in digital light processing 3D printed ceramic samples

Abstract In this study, we investigate how geometric miniaturization affects the sintering densification behavior of alumina cylinders with various wall thicknesses (down to ∼500 µm in green body) fabricated via digital light processing (DLP). As the wall thickness decreased, the density of the sintered samples consistently declined. Microstructural characterization revealed the presence of a crack‐rich surface skin that is ∼500 µm thick. As the wall thickness decreases, the skin's volume fraction rises, and its poor local densification increasingly dominates the part average, leading to an overall decrease in the density of the sintered samples. For the thinnest wall (500 µm) cylinder, macroscopic warping occurred during sintering. We suggest that warping further disrupts particle packing and induces through‐thickness nonuniformity, further impairing densification in addition to the skin‐fraction effect. These results highlight how geometric miniaturization may adversely influence the sintering behavior and final density of DLP‐printed ceramics through distinct densification‐limiting mechanisms.