Keep it Simple: Ceramic Kelvin Cells via Liquid Crystal Display‐Stereolithography Printing

Abstract

Additive manufacturing is the state‐of‐the‐art method for producing complex ceramic parts. For cellular materials, the freedom of design is particularly advantageous, as pore networks and shapes can be tailored. Herein, the direct printing of complex parts with high porosity using the cost‐effective manufacturing method of Liquid Crystal Display‐based stereolithography on low‐cost printers is determined. It is investigated how the architecture of the alumina Kelvin cells topology, their fabrication process, the printing parameters, and the microstructure affect the accuracy and mechanical properties of the printed samples. A notable reduction to a strut thickness of Kelvin cells down to 0.20 mm is achieved corresponding to a reduction of 1.5 compared with the state‐of‐the‐art literature (min. 0.35 mm). Ultrahigh porosities between 89.5% and 97.2% and a maximum compressive strength of 1.84 ± 0.17 MPa are reached due to the dense struts of the structure. Low‐cost and simple vat ceramic photopolymerization with high accuracy printing proves to be a promising candidate for the rapid and cost‐effective fabrication of highly porous and complex ceramic structures.