Optimization of dispersants for high solid content AlN suspensions in digital light processing-based vat photopolymerization technology

Vat photopolymerization (VPP) technology based on digital light processing offers unparalleled advantages for manufacturing complex aluminum nitride (AlN) ceramic components. However, the thermal conductivities of AlN ceramic components fabricated using VPP typically exhibit significant discrepancies compared to those produced using traditional forming processes. The main reason for this is the limitation of the solid content in the AlN ceramic suspensions reported in previous studies, which is usually constrained within 50 vol%. This study systematically investigates the effects of the dispersants KOS110 and KOS163 on the rheological behavior, curing kinetics, and stability of AlN ceramic suspensions. By optimizing the type and concentration of the dispersants, a photocurable AlN ceramic suspension with a high solid content of up to 60 vol% and excellent flow properties is achieved. Using the optimized AlN suspension, high-resolution complex AlN ceramic components are successfully fabricated, exhibiting outstanding thermal conductivity and flexural strength of 183 W/(m & sdot;K) and 331 +/- 8 MPa, respectively. This research will provide theoretical guidance and feasible technical routes for the preparation of complex structure AlN ceramic components with high thermal conductivity.