The performance of vat photopolymerization (VPP) additive manufactured ceramics is critically limited by weak interlayer bonding, which represents a challenge inherent to the layer-by-layer process. However, current research often optimizes stereolithography and sintering as separate stages, overlooking the dynamic evolution of the interlayer. This study introduces a novel paradigm by conceptualizing the interlayer as a dynamic system evolving under photothermal fields. A strategy of cross-process synergistic control, actively interlayer evolution rather than passively reducing defects, was proposed. We systematically investigate key stereolithographic parameters (irradiance, exposure time, and slicing thickness) and sintering protocols, focusing on the collaborative mechanism between photopolymerization dynamics and sintering kinetics in the interlayer. Orthogonal design identifies slicing thickness as the most critical factor. By precisely controlling the ultraviolet (UV) energy input, a controlled incompletely polymerized state is introduced to enhance interlayer bonding via an effective dynamic balance between primary and secondary photopolymerization. Subsequent sintering is tailored to improve the particle packing density at the interlayer. The ZrO₂ ceramic achieves a high flexural strength of 425.89±16.01 MPa and a relative density of 97.21%±0.14% after sintering at 1550 °C for 2 h. This work establishes a framework that links process parameters to interlayer evolution and properties, offering both a practical pathway and a novel theoretical perspective for manufacturing high-performance ceramics.

The inherent brittleness and unpredictable catastrophic fracture of ceramic materials significantly limit their reliability in engineering applications, necessitating innovative approaches to enhance energy absorption capacity and cyclic load tolerance for structural components. This study presents a novel strategy for fabricating high-strength and cyclically-stable Al₂O₃/polymer composites through digital light processing (DLP) 3D printing of triply periodic minimal surface (TPMS) architectures combined with polymer infiltration. Mechanical characterization revealed exceptional quasi-static compressive strength of (201.9 ± 13.2) MPa coupled with remarkable energy absorption capacity reaching (40.1 ± 0.8) MJ/m³. The synergistic combination of TPMS structural design and extrinsic polymer toughening mechanisms induced progressive failure patterns characterized by extensive crack deflection and controlled interfacial debonding. Notably, the architected composites demonstrated outstanding cyclic durability, sustaining over 100 cycles at 60% and 70% maximum stress levels while maintaining 73 cycles at 80% stress level. Mechanical analysis attributed this performance enhancement to the polymer matrix's dual role in stress redistribution and energy dissipation accumulation during cyclic loading. This bioinspired structural design paradigm effectively addresses traditional ceramics' brittleness limitations, demonstrating significant potential for engineering applications in extreme environments requiring damage tolerance and load cycling reliability.