Design, manufacturing and properties of controllable porosity of ceramic filters based on SLA-3D printing technology

The ceramic foam filters are commonly applied in metal casting. However, this kind of filter has a number of drawbacks, such as weak impact resistance, uncontrollable technical parameters, and a long producing cycle. Our work developed a better manufacturing method for ceramic filters based on SLA-3D printing technology in which the structure of filters can be designed according to demands of porosity and hole density. Firstly, it is to propose a ceramic filter model with good mechanical properties under various porosities and hole densities using mechanical simulation and topology optimization. Secondly, SLA-3D printing technology was used to manufacture ceramic filter models with various characteristics. The results demonstrate that the porosity can be achieved with a wide range, and the higher porosity and hole density can approach 90% and 50 PPI, respectively. The preparation error of the internal pillars inside the filters model also can be revised to precisely control the porosity error of filters. Finally, the pore characteristics and compressive performance of the SLA printed ceramic filters were much better than that of the ceramic foam filters.