Additive manufacturing of ceramics via the laser powder bed fusion process

Additive manufacturing (AM) of ceramics presents both exciting opportunities and significant challenges, particularly with the laser-based AM processes. Ceramics are known for their special properties, such as high strength, corrosion resistance, and temperature stability, but their inherent brittleness and high processing demands make AM more complex. This review provides an updated overview of the most common AM techniques for ceramics, including direct energy deposition, binder jetting, laminated object manufacturing, and material extrusion-based techniques. However, the focus is placed on the laser powder bed fusion (LPBF) of ceramics, a technique that has gained increasing attention for its ability to fabricate complex ceramic parts with enhanced quality. The review delves into the key causes of critical defects commonly observed in LPBF, such as porosity, cracking, spattering, and surface roughness. Recent advancements in addressing these issues are discussed, along with the limitations of current defect prevention strategies. Furthermore, the review provides an updated analysis of the mechanical properties of LPBF-fabricated ceramics, giving insights into how processing parameters influence the performance of ceramic LPBF-printed parts. Modeling and simulation techniques are also reviewed, highlighting their role in enhancing understanding of ceramic behavior during LPBF. Overall, this review highlights recent progress and current challenges in ceramic AM techniques, while exploring future research opportunities, such as process optimization and defect prevention strategies.