Stereolithographic additive manufacturing of ceramic components with functionally modulated structures

Stereolithographic additive manufacturing (STL-AM) was newly developed as a direct forming process for fine ceramic components. Two-dimensional (2D) cross sections were created through ultraviolet laser drawing on spread photosensitive resin paste, including ceramic nanoparticles, and three-dimensional (3D) composites were sterically printed by layer laminations and interlayer joining. The formed precursors were dewaxed and sintered along optimized heat treatment patterns. Functionally geometric modulations by computer-aided design, manufacture, and evaluation (CAD/CAM/CAE) were successively reviewed. Fluctuated features were introduced into solid components through inverse Fourier transformations. Fluid flow profiles in aqueous environments were numerically simulated to profile smooth streamlines. Graded porosities were elaborated in calcium phosphate scaffolds of artificial cancerous bones. The coordination number and aspect ratios of the microlattices were systematically modulated for cytapheresis and metabolism. Structural dimensions with integer or fractional values were estimated to be able to comprehensively discuss the compatibilities of spatial element dispersions and directional mass transfers.