Realization of complex-shaped and high-performance alumina ceramic cutting tools via Vat photopolymerization based 3D printing: A novel surface modification strategy through coupling agents aluminic acid ester and silane coupling agent

It is still a challenge to prepare high-performance ceramics due to the inherent problems of poor compatibility between ceramic powder and photosensitive resin in Vat photopolymerization. Herein, we used two types of coupling agents, aluminic acid ester and silane coupling agent, to modify Al2O3 ceramic powder based on transesterification reactions. In addition, after pressureless sintering, hot isostatic pressing sintering was followed to further improve the mechanical performance of the Al2O3 ceramic. Furthermore, Al2O3 ceramic cutting tools with chip breaker grooves were prepared based on vat photopolymerization and adopted for cutting for the first time. Simulation and experimental results showed that the as-prepared ceramic cutting tool with grooves has the best surface processing quality and the medium flank wear amount compared with that without grooves and even Kyocera commercial ceramic cutting tool. The results open a new avenue for the preparation of high-performance and complex-shaped ceramic cutting tools in the future.