Single-Step Thermal Debinding for Ceramics Vat Photopolymerization in Less than 30-Minutes

Abstract

Vat photopolymerization (VPP) 3D printing of ceramics is known for producing high-resolution, high-quality ceramic parts, particularly in the dental industry. However, the thermal debinding (TD) process in ceramic VPP is time- and energy-intensive due to the large binder content (40–60 vol%), limiting its widespread adoption. The TD step often takes 20 to 100 hours, significantly increasing manufacturing costs and preventing the use of VPP for processes requiring fast turnaround times. Here, we demonstrate an ultrafast thermal debinding (UFTD) process for zirconia parts fabricated by VPP, achieving complete binder removal in under 30 minutes. By utilizing the unique advantages of vacuum pyrolysis and rapid heating with porous graphite felts, we accelerate binder removal while maintaining the structural integrity of the ceramic parts. Our results show a 40–200-fold reduction in processing time and a 3,500-fold decrease in energy consumption compared to conventional thermal debinding, with the UFTD-processed samples exhibiting properties comparable to conventionally processed 3D-printed zirconia. This approach provides a promising method for faster, energy-efficient production of zirconia parts, while the findings also offer valuable insights into the mechanisms of UFTD, paving the way for its application in other ceramic-based additive manufacturing processes.

Keywords: Ceramic, Vat photopolymerization (VPP), Digital light processing (DLP), Thermal Debinding, Zirconia.