Micro Mechanical Machining of 3D Printed Ceramic Structures

Ceramics are widely used in aerospace and medical applications due to their excellent corrosion and heat resistance. However, their high hardness and brittleness often lead to cracking during machining, making it difficult to fabricate high-precision components. Additive manufacturing via 3D printing enables complex ceramic geometries but typically causes volumetric shrinkage and surface distortion during sintering, reducing dimensional accuracy. In this study, micro grinding using a polycrystalline diamond (PCD) tool was employed after 3D printing to improve the dimensional precision of sintered zirconia structures. The effects of feed rate and spindle speed were systematically investigated, indicating that lower feed rates and higher spindle speeds—corresponding to smaller feed per revolution and higher cutting speeds—can improve surface finish by reducing scratching and vibration. The machined features were evaluated in terms of roundness and straightness, suggesting that combining 3D printing with PCD micro grinding can effectively enhance both surface integrity and geometric accuracy, offering a promising approach for high-precision ceramic fabrication.