Stereolithography coupled with spark plasma sintering to produce Ti-6Al-4V complex shapes

Coupling ceramic stereolithography (SLA) and spark plasma sintering (SPS) is possible by the deformed interface approach. Such innovative approach enables the production of highly complex shapes through the high resolution of SLA and the highly controllable microstructures of SPS. This process circumvents at the same time the complex thermal history of other additive manufacturing methods like selective laser melting (SLM) and all issues of complex shapes production in pressing devices like SPS. The production of Ti-6Al-4V thick conical shape and thin complex turbine blade shape is presented is this article. The powder and interface co-sintering requires a finite element (FEM) simulation tool to predict the Ti-6Al-4V high temperature sintering and the impact of the interface on the shape distortions. The sintering mechanisms, microstructures, and mechanical properties were characterized for all the shapes. This work shows the prototyping of titanium complex parts by SLA coupled to SPS is on the verge to become possible.