Direct laser fusing to form ceramic parts

This paper proposes a new layered manufacturing method for forming a ceramic part, ceramic laser fusing (CLF). It involves mixing ceramic powder with an inorganic temperature-resistant binder to form a thin green body layer. Due to laser radiation, the green body layer is melted locally and the substrate, which is also formed by green body layers, underneath it is wetted by the melted phase. This process can minimize the "balling effect". In comparison with other layered manufacturing methods, in hand of CLF the ceramic green layer is fused together directly by laser exposure, requiring no conventional sintering post process. Furthermore, during laser fusion this process is able to compensate dimensional error due to shrinkage. Therefore, CLF is suitable for producing complex part with less distortion. Despite crack sensitivity, this process may have a potential to fabricate investment mould for precision casting.