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Digital light processing 3D printing can be applied to fabricate complex silicon nitride (Si 3 N 4) components. However, because of the surface hydroxyl groups and large refractive index, it is still a foremost challenge to realize a stable photosensitive Si 3 N 4 slurry with combined benefits of low viscosity and large curing depth. In this study, we propose a new formulation strategy to prepare Si 3 N 4 slurry. Starting from the optimization of monomer ratio, we have systematically optimized powder particle size, dispersant and photoinitiator on the rheological properties and curing properties of Si 3 N 4 slurry. Specifically, we have fabricated a stable photosensitive Si 3 N 4 slurry (48 vol%) with a viscosity of 2.09 Pa s (30 s−1), a critical curing energy of 126.09 mJ/cm2 and a maximum curing depth of 80 µm. Finally, based on this optimized slurry, we have successfully obtained complex Si 3 N 4 green body with no defect, which demonstrates great potential to fabricate arbitrary complex ceramic components for various applications. [ABSTRACT FROM AUTHOR]

The ability of Hypermer KD1 to disperse high solids loading reaction sialon suspensions for slip casting has been characterised. It has been found to be a very effective dispersant in organic media of 60-vol.% MEK and 40-vol.% Ethanol, yielding fluid and highly homogeneous suspensions. The effects of added amounts of KD1 have been observed through adsorption data, sedimentation tests and rheology measurements. KD1 imparts low viscosity and stability to the suspension. It has been found that 3-wt.% addition of KD1, based on the weight of reaction sialon powders, results in a very stable and high flowable suspension with near Newtonian flow behavior. Less amounts of dispersant lead to unstable suspensions with obvious shear thinning flow behaviors, while adding excessive dispersant leads to high viscosities, especially at high solids loading. Measuring the pore size distribution of green bodies from different suspensions has proved the effects of dispersant amounts on dispersing the slurries and on slip casting performance. [Copyright &y& Elsevier]