The 3DP process has been modified to directly fabricate high green density parts using submicron powder. The slurry-based 3DP process deposits the powder bed by spraying a dispersed slurry of the component material onto a piston. Alumina, silicon nitride, and lead zirconate titanate components with green densities as high as 67% have been fabricated by the slurry-based 3DP process. Solution phase binder systems have proven to be successful for the new process. Substantially improved surface

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... sh over the conventional dry powder-based 3DP process has been demonstrated. Layer heights less than 50 Jlm can be prepared with this process. Thus, the stepped surface topography commonly observed in solid free form parts is substantially reduced.