Manufacturability and geometrical limitations of β-tricalcium phosphate-filled resins using LCD stereolithography

Additive manufacturing of bio-ceramics using LCD stereolithography allows the creation of ceramic parts with unprecedented resolution for various medical applications. However, the potential of this technology can only be fully harnessed if the manufacturability of critical geometries is accurately characterized. Thus, this contribution provides a guide with examples for the characterization and analysis of the printability of β-tricalcium phosphate-filled resins using LCD stereolithography. Characterized features include the minimum bore diameter, the minimum wall thickness of free-standing walls and cylindrical pins, the maximum unsupported bridging and overhang and the maximum abrupt thickness changes of cylindrical components. The analysis addresses limitations and factors affecting manufacturability of bio-ceramic-filled resins, and gives recommendations for design and processing parameters. In addition, TGA analysis is presented as a guide for the selection of suitable debinding and sintering schedules for an optimized microstructure and functionality.