Numerical simulation of cold isostatic pressed alumina parts produced by selective laser sintering and part shape optimization

Cold isostatic pressing (CIP) combined with selective laser sintering (SLS) is a practical and effective process for producing complex ceramic components with high density. This paper focused on the numerical simulation of alumina SLSed components during CIP for near net shaping. The Drucker–Prager-Cap plasticity model was used to predict the densification behavior and deformation of the alumina/epoxy resin composite powders. CIP experiments were conducted to determine the required parameters for the model. The simulative final dimensions and densities agree well with the experimental results, with the relative error less than 1.7% in the forming plane. Structure optimization was made to the part and bag, which proves conducive to reducing distortion. The effects of the part fillet radius on shape accuracy were investigated, and the optimal fillet radius can be determined by simulation. Eventually, the alumina part reached its highest density of 94.5% through optimized CIP and sintering process.