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<p>In digital light polymerization (DLP) based 3D printing of ceramic substrates, higher solid loading generally benefits the product’s microstructure and performance by improving interlayer bonding and enhancing dimensional accuracy. However, in recent years, significant challenges have arisen in preparing high-solid-content (≥ 75&#xa0;wt%) slurries via DLP based 3D printing technologies, because higher ceramic loading often causes severe particle agglomeration and deteriorates rheology, which compromises printability and quality of the final parts. In this study, the synergistic action of a steric dispersant (BYK110) and a silane coupling agent (KH570) was used to formulate silica-based slurries with an ultra-high solid content (80&#xa0;wt%), enabling high-precision DLP printing. As the solid content of the ceramic slurry rose from 76 to 80 wt%, its viscosity climbed from 1.1 to 4.6&#xa0;Pa·s, yet remained within the range acceptable for the 3D-printing process. Despite its higher solid content, the ceramic slurry formulated with the dual-dispersant system exhibited lower viscosity than the lower-solid-content slurry prepared with a single dispersant. The silane strengthened particle-resin interfacial bonding, whereas the dispersant’s steric suppressed particle agglomeration. For samples with 76&#xa0;wt% solid content, the sintering shrinkage in the X, Y and Z directions for the dual-dispersant system was 2.21 ± 0.18%, 3.15 ± 0.33% and 1.51 ± 0.24%, respectively, approximately 60–80% lower than that of the single-dispersant system. The dispersant design strategy proposed in this study enabled the preparation of high-solid-content, low-viscosity ceramic slurries, offering a useful reference for the fabrication of ceramic substrates in electronic packaging applications.</p>

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The preparation of 3D printed silica ceramics with high solid content by synergistic dispersants

  • 期刊论文

  • 发表日期：

    2026年3月12日

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  • Jie Zhang,
  • He Li,
  • Paolo Colombo

摘要

In digital light polymerization (DLP) based 3D printing of ceramic substrates, higher solid loading generally benefits the product’s microstructure and performance by improving interlayer bonding and enhancing dimensional accuracy. However, in recent years, significant challenges have arisen in preparing high-solid-content (≥ 75 wt%) slurries via DLP based 3D printing technologies, because higher ceramic loading often causes severe particle agglomeration and deteriorates rheology, which compromises printability and quality of the final parts. In this study, the synergistic action of a steric dispersant (BYK110) and a silane coupling agent (KH570) was used to formulate silica-based slurries with an ultra-high solid content (80 wt%), enabling high-precision DLP printing. As the solid content of the ceramic slurry rose from 76 to 80 wt%, its viscosity climbed from 1.1 to 4.6 Pa·s, yet remained within the range acceptable for the 3D-printing process. Despite its higher solid content, the ceramic slurry formulated with the dual-dispersant system exhibited lower viscosity than the lower-solid-content slurry prepared with a single dispersant. The silane strengthened particle-resin interfacial bonding, whereas the dispersant’s steric suppressed particle agglomeration. For samples with 76 wt% solid content, the sintering shrinkage in the X, Y and Z directions for the dual-dispersant system was 2.21 ± 0.18%, 3.15 ± 0.33% and 1.51 ± 0.24%, respectively, approximately 60–80% lower than that of the single-dispersant system. The dispersant design strategy proposed in this study enabled the preparation of high-solid-content, low-viscosity ceramic slurries, offering a useful reference for the fabrication of ceramic substrates in electronic packaging applications.