Study of mixing process of low temperature co-fired ceramics photocurable suspension for digital light processing stereolithography

Abstract The Low Temperature Co-fired Ceramic (LTCC) materials are highly used for high frequency devices required for high-speed data communications, representing an attractive material for electronic applications with a direct industrial applicability. The development of a photocurable LTCC suspension for Digital Light Processing Stereolithography (DLP-SLA) technology is presented in this work. The LTCC suspension, with an optimal solid load of 40.4 vol%, was characterized along its preparation regarding the rheological behaviour, dispersant content, particle size distribution in function of milling time and photocuring properties in a visible light range. The effect of the particle size change, through ball milling, on viscosity and photocuring behaviour was studied, achieving an optimal mixing range time, which highlights the importance of the manufacturing standardization of the photocurable suspensions. The optimized suspension presents a viscosity of 3.6 Pa·s at shear rate of 2 s-1, a sensitivity of 41 μm and a critical energy dose of 15 mJ·cm-2. The printing process was successfully achieved, demonstrated by some defect-free printed pieces.