Characterization of the physics of photopolymer curing and formulation effects of highly filled slurries during additive ceramic core manufacture

The proposed research focuses on the key role that ultraviolet curing of highly filled ceramic slurries plays in achieving fine features and dimensional capability in the production of ceramic components by additive layer manufacturing techniques. Laboratory procedures to characterise the curing process in combination with modelling techniques will be developed to understand residual stress development during component build, de-bind and sintering. These techniques will subsequently quantify the contribution of curing related stresses to the interlayer strength and shrinkage anisotropy. The mechanistic understanding developed will subsequently be used to understand how the formulation affects fine feature formation and dimensional stability.

Project Objectives:
-Develop laboratory procedures to characterise the curing process, and the impact on residual stresses and corresponding strains and dimensional movement
-Develop modelling techniques to predict the behaviour of photopolymer curing residual stresses, strains and dimensional movement.
-Characterise the effect of photopolymer curing residual stresses on inter-layer strength
-Characterise the effect of formulation and machine parameters on the development of residual stress, and subsequent capability to produce fine features in silica based additive ceramics whilst maintaining overall dimensional stability