Additive manufacturing di materiali ceramici per applicazioni nella microelettronica = Additive manufacturing of ceramic materials for microelectronics applications

This thesis explores the additive manufacturing of alumina ceramic components using Digital Light Processing (DLP), targeting their application in microelectronics and thermal management systems. As the demand for miniaturized, high-performance ceramic parts increases, vat photopolymerization (VPP) offers a promising route for fabricating complex geometries with high precision and functional integrity. Despite this, challenges remain in optimizing exposure settings, ensuring interlayer adhesion, and achieving reliable mechanical and thermal properties in sintered parts. To address these, a complete DLP workflow was implemented using AdmaPrint A13C slurry and the Admaflex 130 Entry system. Depth of Cure (DoC) calibration was performed to define exposure parameters for two-layer thicknesses (30 µm and 50 µm), which were then applied during slicing and printing of both bar and disc-shaped samples. Post-print procedures included TPM solvent cleaning and ultrasonic treatment, followed by debinding and sintering. Dimensional shrinkage, porosity (via Archimedes method), mechanical properties (via three-point bending), and thermal conductivity (via GHFM-01 testing) were evaluated. The results demonstrated consistent shrinkage behavior (~27–55%), low open porosity (~1.25%), and reliable mechanical performance, with an average flexural strength of 228.1 MPa and Young’s modulus of 221.6 GPa. Thermal conductivity values ranged from 1.98 to 2.44 W/m·K over a temperature range of 100–250 °C. In the final phase, a custom-designed alumina thermal dissipator was simulated to assess its heat dissipation potential, applying the experimentally derived thermal parameters. This work validates the use of DLP-printed alumina in structural and thermal roles, and presents a repeatable, digitally integrated workflow that bridges the gap between laboratory research and industrial ceramic manufacturing.