Fabrication of complicated ceramic parts by gelcasting based on additive manufactured acetone-soluble plastic mold

Zirconia ceramic green parts were prepared by gelcasting using acetone-soluble plastic molds printed by fused deposition modeling (FDM) method. The demolding process was then completed by acetone immersion and manual removal. The dispersant content, solid content and ball milling parameters were investigated by analyzing the rheological properties of the zirconia slurry. The mechanical properties and microstructure of furnacesintered samples with different solid content from 48 vol% to 54 vol% were also tested. Sintered sample prepared from the slurry with 50 vol% solid content had the highest relative density (99.57 +/- 0.49%), bending strength (947.8 +/- 8.8 MPa) and Vickers hardness (1371.2 +/- 225.8 HV). The research showed a positive and practical approach to fabricate ceramic parts with complex shape or structure by gelcasting based on additive manufactured soluble mold.