硅酸盐学报

陶瓷铸型粉床增材制造研究进展与应用

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周佳杰 ² , 孙志斌 ² , 蒋文明 ³ , 刘生发 ² , 周士翔 ⁴ , 龚小龙 ² , 吴甲民 ³ , 闫春泽 ³ , 刘凯 ¹^,² , 史玉升 ³

硅酸盐学报 | 综合评述 2026,54(9): 3000-3012

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硅酸盐学报 |综合评述 2026 , 54 (9) : 3000 -3012

陶瓷铸型粉床增材制造研究进展与应用

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周佳杰², 孙志斌², 蒋文明³, 刘生发², 周士翔⁴, 龚小龙², 吴甲民³, 闫春泽³, 刘凯¹^,², 史玉升³

作者信息

^1．武汉理工大学，硅酸盐科学与先进建材全国重点实验室，武汉 430070

^2．武汉理工大学材料科学与工程学院，武汉 430070

^3．华中科技大学材料科学与工程学院，材料成形与模具技术全国重点实验室，武汉 430074

^4．武汉理工大学交通与物流工程学院，武汉 430063

通讯作者:

刘凯（1987—），男，博士，教授。

作者简介:

周佳杰（2001—），男，硕士研究生。

Development on Powder Bed Additive Manufacturing for Ceramic Molds

Jiajie ZHOU², Zhibin SUN², Wenming JIANG³, Shengfa LIU², Shixiang ZHOU⁴, Xiaolong GONG², Jiamin WU³, Chunze YAN³, Kai LIU¹^,², Yusheng SHI³

Affiliations

^1.State Key Laboratory of Silicate Materials for Architectures, Wuhan University of Technology, Wuhan 430070, China

^2.School of Materials Science and Engineering, Wuhan University of Technology, Wuhan 430070, China

^3.State Key Laboratory of Materials Processing and Die & Mould Technology, School of Materials Science and Engineering, Huazhong University of Science and Technology, Wuhan 430074, China

^4.School of Transportation and Logistics Engineering, Wuhan University of Technology, Wuhan 430063, China

Corresponding Author:

{LIU} Kai (1987-), male, Ph.D., Professor. E-mail: victor_liu@whut. edu. Cn

ZHOU Jiajie (2001-), male, Master candidate. E-mail: jiajiezhou2001@163.com

出版时间: 2026-08-18 doi: 10.14062/j.issn.0454-5648.20260113

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摘要

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陶瓷铸型因其热稳定性好、强度高、精度高等优点，被用于航空航天、能源装备、医疗器械等领域关键复杂铸件的成形加工。当前陶瓷铸型制造主要依赖于模具成形，复杂结构成形难度大、通常需要拼合组装，导致研制周期长、拼接处力学性能低等问题。粉床增材制造技术可实现无模整体快速成形，以此制备复杂高性能陶瓷铸型，为复杂铸件的短流程制造提供了新途径。本文总结了黏结剂喷射和激光选区烧结两大类粉床增材制造技术在复杂陶瓷铸型成形方面的最新研究进展，重点阐述了陶瓷粉末材料、打印参数等对陶瓷铸型性能的影响，以及陶瓷铸型后的性能调控方法，并介绍了陶瓷铸型粉床增材制造技术的应用情况。最后，对未来发展方向进行了展望。

关键词

陶瓷铸型 / 增材制造 / 铸造 / 黏结剂喷射 / 激光选区烧结

Abstract

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Ceramic molds, including cores for internal cavities and shells for outer contours, are essential components for precision casting of complex parts in aerospace, energy equipment, and medical devices, due to their excellent thermal stability, high strength, and dimensional accuracy. As high-end castings evolve toward lightweight and integrated designs, conventional mold-dependent methods such as injection molding and gel casting have limitations. These techniques require splicing for complex structures, leading to long development cycles, poor joint performance, and high costs. Powder bed additive manufacturing (PBAM), including binder jetting additive manufacturing (BJAM) and selective laser sintering (SLS), enables mold-free, rapid, and integral fabrication of complex ceramic molds, offering a pathway for efficient short-process manufacturing.

This review systematically summarizes recent development on BJAM and SLS for ceramic mold fabrication, focusing on the effects of powder materials and printing parameters on the mold performance, post-processing regulation methods, engineering applications, and future directions. In BJAM, ceramic molds are formed via selectively depositing a liquid binder onto powder layers. Powder properties including particle size distribution, flowability, and composition critically determine green density and sintered properties. Common materials like Al₂O₃ and CaO are widely used, but they require additives such as sintering aids (i.e., nano-sized Al₂O₃, CuO-TiO₂) and shrinkage compensators (i.e., Al powder, and SiO₂). Key printing parameters, particularly binder saturation and layer thickness, significantly affect the green strength and surface quality. Post-processing through sintering optimization and vacuum infiltration with silica sol or nano-sized additives is essential to achieve required mechanical properties and porosity. BJAM features a high efficiency, a broad material adaptability, and a support-free fabrication, making it suitable for large ceramic molds with complex internal structures. In SLS, ceramic molds are formed by high-energy laser selectively melting polymer-coated or binder-mixed ceramic powders without liquid binders, providing a higher green strength. The powder system comprises ceramic matrix materials (i.e., SiO₂, Al₂O₃), organic or inorganic binders (i.e., phenolic resin, B₄C), and functional additives to enhance flowability and laser absorption. Critical parameters like laser power, scanning speed, layer thickness, and hatch spacing determine energy input and part quality. Post-processing via sintering and infiltration is required to achieve high-temperature strength, creep resistance, and dimensional stability. SLS delivers green bodies with a high initial density, ideal for complex thin-walled molds and high-precision applications in directional solidification casting.

BJAM and SLS both are applied in producing ceramic cores and shells for turbine blades and impellers, demonstrating complex cooling passages, high surface finish, and excellent high-temperature performance that meet stringent casting requirements.

Summary and prospects

The existing PBAM achieves phased results. To further promote its large-scale application in the fabrication of high-performance ceramic molds, there are the following aspects. There is an urgent need to develop additive manufacturing-specific powders and functional binder systems. For BJAM process, composite ceramic powders with favorable flowability and optimized gradation should be developed, and multifunctional binder systems should be designed to reduce the dependence on post-processing performance regulation. For SLS process, it is necessary to develop ceramic/binder phase composite powders with high laser absorptivity and excellent sintering activity, so as to reduce the difficulty of subsequent sintering and improve the strength of ceramic molds. Dedicated printing systems and post-processing equipment suitable for the multi-material integrated forming of ceramic molds should be developed. Key technologies such as precise multi-material powder spreading and delivery, as well as synchronous manufacturing of ceramic cores and shells, should be prioritized to realize high-precision and high-efficiency integrated forming of ceramic molds with complex structures. Regarding the performance regulation, improving the high-temperature strength, creep resistance and dimensional stability of ceramic molds becomes an emphasis. The porosity and relative density can be synergistically regulated to balance the contradiction between high strength and easy core leaching by means of material design, printing parameter adjustment and post-processing process optimization, so as to meet the stringent performance requirements of ceramic molds for high-end castings.

Key words

ceramic mold / additive manufacturing / casting / binder jetting / selective laser sintering

引用本文

周佳杰, 孙志斌, 蒋文明, 刘生发, 周士翔, 龚小龙, 吴甲民, 闫春泽, 刘凯, 史玉升. 陶瓷铸型粉床增材制造研究进展与应用. 硅酸盐学报, 2026 , 54 (9) : 3000 -3012 . DOI: 10.14062/j.issn.0454-5648.20260113

Jiajie ZHOU, Zhibin SUN, Wenming JIANG, Shengfa LIU, Shixiang ZHOU, Xiaolong GONG, Jiamin WU, Chunze YAN, Kai LIU, Yusheng SHI. Development on Powder Bed Additive Manufacturing for Ceramic Molds[J]. Journal of the Chinese Ceramic Society, 2026 , 54 (9) : 3000 -3012 . DOI: 10.14062/j.issn.0454-5648.20260113

基金

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国家重点研发计划青年科学家项目(2021YFB3703100)
2023年湖北省重大攻关项目（JD）(2023BAA023)
湖北省自然科学基金面上项目(2025AFB457)
中南大学粉末冶金全国重点实验室开放课题(Sklpm-KF-2025008)

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2026年第54卷第9期

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文章信息

doi: 10.14062/j.issn.0454-5648.20260113

接收时间：2026-02-28
首发时间：2026-10-22
出版时间：2026-08-18

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收稿日期：2026-02-28
修回日期：2026-03-16

基金

国家重点研发计划青年科学家项目(2021YFB3703100)

2023年湖北省重大攻关项目（JD）(2023BAA023)

湖北省自然科学基金面上项目(2025AFB457)

中南大学粉末冶金全国重点实验室开放课题(Sklpm-KF-2025008)

作者信息

^1．武汉理工大学，硅酸盐科学与先进建材全国重点实验室，武汉 430070

^2．武汉理工大学材料科学与工程学院，武汉 430070

^3．华中科技大学材料科学与工程学院，材料成形与模具技术全国重点实验室，武汉 430074

^4．武汉理工大学交通与物流工程学院，武汉 430063

通讯作者:

刘凯（1987—），男，博士，教授。

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https://castjournals.cast.org.cn/joweb/gsyxb/CN/10.14062/j.issn.0454-5648.20260113

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2种不同金属材料的力学参数

科 Family	属数 Number of genus	种数 Number of species	占总种数比例 Percentage of total species (%)	属 Genus	种数 Number of species	占总种数比例 Percentage of total species (%)
鹅膏菌科Amanitaceae	2	11	5.26	鹅膏菌属 Amanita	10	4.78
小菇科 Mycenaceae	2	12	5.74	丝盖伞属 Inocybe	5	2.39
多孔菌科 Polyporaceae	8	14	6.70	蜡蘑属 Laccaria	5	2.39
红菇科 Russulaceae	3	23	11.00	小皮伞属 Marasmius	6	2.87
				小菇属 Mycena	11	5.26
				光柄菇属 Pluteus	5	2.39
				红菇属 Russula	17	8.13
				栓菌属 Trametes	5	2.39

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