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Fabricating SiC ceramics via the digital light processing (DLP) technology is of great challenge due to strong light absorption and high refractive index of deep-colored SiC powders, which highly differ from those of resin, and thus significantly affect the curing performance of the photosensitive SiC slurry. In this paper, a thin silicon oxide (SiO2) layer was in-situ formed on the surface of SiC powders by pre-oxidation treatment. This method was proven to effectively improve the curing ability of SiC slurry. The SiC photosensitive slurry was fabricated with solid content of 55 vol% and viscosity of 7.77 Pa·s (shear rate of 30 s−1). The curing thickness was 50 μm with exposure time of only 5 s. Then, a well-designed sintering additive was added to completely convert low-strength SiO2 into mullite reinforcement during sintering. Complex-shaped mullite-bond SiC ceramics were successfully fabricated. The flexural strength of SiC ceramics sintered at 1550 ℃ in air reached 97.6 MPa with porosity of 39.2 vol%, as high as those prepared by spark plasma sintering (SPS) techniques.
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