UFTD method achieves 30-minutes binder removal in 3D printed zirconia | VoxelMatters - The heart of additive manufacturing

A new ultrafast thermal debinding (UFTD) technique developed by researchers at the University of Texas (UT Dallas) enables complete binder removal in under 30 minutes. The team used 3y zirconia slurries and a ceramic stereolithography (vat photopolymerization) 3D printer from Tethon 3D.

“Think about being able to print a crown and then sinter in 30 minutes,” Tethon 3D CEO Trent Allen told VoxelMatters. “In ceramic AM, we can offer some of the most affordable materials and hardware. We are hopeful we can provide a popular solution to the dental market, which is much more price-sensitive than the broader healthcare segment.”

Vat photopolymerization (VPP) is a powerful 3D printing method for ceramics, offering high-resolution and detailed structures. However, the conventional thermal debinding (TD) process, which requires removing binders before sintering, takes between 20 and 100 hours. This time-intensive process increases costs and delays production, limiting VPP’s industrial applications.

By leveraging vacuum pyrolysis and rapid heating with porous graphite felts, UFTD accelerates binder removal while preserving structural integrity. This advancement reduces processing time by 40 to 200 times and cuts energy consumption by 3,500 times compared to conventional methods.

The UFTD process incorporates vacuum conditions and high-speed heating cycles for efficient debinding. The thermal profile includes heating rates of approximately 100°C per second with specific dwell periods at multiple temperatures, culminating in final sintering at 1450°C for 2.5 minutes. This optimized approach eliminates polymer residues and prepares zirconia parts for high-quality sintering without cracks or defects.

Compared to traditional thermal debinding, which takes up to 100 hours with energy-intensive sintering processes, UFTD significantly reduces time and energy use. The transition from conventional thermal oxidation to vacuum pyrolysis accelerates polymer decomposition and facilitates rapid gas evacuation, which minimizes internal stress, material waste, and environmental impact.

Despite the rapid heating, UFTD maintains excellent mechanical properties. The porosity levels of UFTD-processed samples match those of conventionally debinded parts, remaining around 4.2 to 4.3 percent. The grain structure remains well-formed, with UFTD samples exhibiting larger grains while preserving a Vickers Hardness of up to 15.5 GPa, comparable to traditional processes.

The UFTD method opens new possibilities for ceramics in industries requiring fast production cycles, such as dental applications, aerospace components, and precision-printed ceramic insulators for electronics. UFTD represents a breakthrough in ceramic additive manufacturing by slashing debinding time from days to minutes while maintaining part quality. This advancement positions VPP as a highly efficient method for industrial-scale ceramic production, ensuring faster turnaround, lower costs, and minimal energy use.