Optimization of Debinding Process to Tailor Microstructure and Mechanical Properties of Kaolin Ceramics

ABSTRACT

Digital light processing (DLP) 3D‐printed kaolin ceramics show great potential in refractories and electronic packaging, yet unreasonable debinding causes uneven binder decomposition, poor densification, and low mechanical strength. Herein, the effects of debinding temperature, holding time, and heating rate on the microstructure and mechanical performance of DLP kaolin ceramics were systematically explored. The optimal debinding condition was identified as 500°C, 0 min, and 1°C/min. The optimized sample achieves a flexural strength of 98.95 ± 1.98 MPa, a bulk density of 3.04 ± 0.15 g/cm ³ , and a low porosity of 0.38 ± 0.02%. Improper debinding induces microcracks and performance deterioration. This work clarifies the debinding regulation mechanism and provides guidance for high‐performance 3D‐printed kaolin ceramics.