Abstract
Porous alumina parts were prepared using a lithography-based ceramic manufacturing process (Lithoz CF7500). Green parts were subjected to debinding and sintering processes to produce mechanically strong parts. The photopolymer binder was found to be highly sensitive to heating rate. The primary alumina particles contained within the binder were quasi-spherical and >100 nm diameter. By deliberately under-sintering it was possible to produce porous structures with up to 45% open porosity, and sharp, unimodal pore size distributions, with pores in the range 40-70 nm. When no sintering dwell time was used, the porosity-type was almost exclusively open. However, when a sintering dwell was employed at 1500°C, the percentage of closed porosity increased at the expense of open porosity. Such regularly-shaped parts with open, interconnected porosity are candidates as monoliths for separation science applications.
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