Using the Selective Laser Sintering (SLS) process, both flexural test bars and 3D fuel injector components have been fabricated with zirconium diboride (ZrB2) powder. Stearic acid was selected as the binder. Values of SLS process parameters were chosen such that the green parts could be built with sharp geometrical features and that the sintered parts could have good mechanical properties. After binder burnout and sintering, the SLS fabricated ZrB2 test bars achieved 80% theoretical density, and the average flexural strength of the sintered samples was 195 MPa. These values demonstrate the feasibility of the SLS process for freeform fabrication of 3D parts with the ultra high temperature ceramic.

Meeting Name

19th Annual International Solid Freeform Fabrication Symposium (2008: Aug. 4-6, Austin, TX)


Mechanical and Aerospace Engineering

Second Department

Materials Science and Engineering


This work was supported by the Air Force Research Laboratory under Contract FA8650- 04-C-5704.

Keywords and Phrases

Binders; Mechanical properties; Sintering; Three dimensional; Zirconium compounds; Freeform fabrication; Geometrical features; Process parameters; Selective laser sintering; Sintered samples; Theoretical density; Ultra-high-temperature ceramics; Zirconium diboride; Laser heating

Document Type

Article - Conference proceedings

Document Version

Final Version

File Type




Publication Date

06 Aug 2008