Development of an Indirect Solid Freeform Fabrication Process Based on Stereolithography and Gelcasting for Ceramic Casting Molds

In this paper, an indirect solid freeform fabrication (ISFF) process was developed to rapidly fabricate ceramic casting molds by combining stereolithography with gelcasting technology. To realize this method, the stereolithography apparatus was used to fabricate a resin mold, and then aqueous ceramic slurry was cast into the resin mold and in situ polymerized to form a wet green body of ceramic casting mold. Freeze drying, pyrolyzing and sintering completed the manufacturing route. Finally, the ceramic casting mold with complex ceramic cores was obtained, and a car radiator with deep grooves was produced to verify the validity and feasibility of the method.