Binder jetting printing of zirconia structures via grading powder and epoxy binder

The binder jetting (BJ) process shows significant superiority in manufacturing ceramic parts with a complex structure. The performance of the green part is highly reliant on the features of raw materials. A kind of grading zirconia powder M0 was designed, its intrinsic characteristics including microstructure, size and size distribution, bulk density, porosity, hall velocity and spread performance were systematically evaluated. The design principles of M0 were illustrated in detail. Meanwhile, a kind of organic epoxy binder was prepared and its properties including density, viscosity and surface tension were estimated. The jet ability of binder was evaluated quantitatively. The compatibility and bonding strength between binder and powder were assessed through contact angle, infiltration time and microstructure of M0. As a result, M0 and epoxy binder can be successfully applied in the printer, the zirconia structure with good dimensional accuracy (shrinkage rate ≤ ±2%) and flexible strength (1.74 ± 0.28 MPa) were achieved.