The integration of digital manufacturing and ceramic engineering presents transformative opportunities for tailoring ceramic properties through process optimization. This study investigates the influence of powder morphology and process parameters on the printability and performance of alumina (Al₂O₃) components fabricated via binder jetting. Alumina powders with varied particle shapes and size distributions were characterized for shape factor, flow rate, and bulk properties to assess their suitability for layer-wise deposition. Print accuracy and resolution were evaluated by fabricating geometrically standardized specimens, followed by dimensional analysis using 3D scanning. Experimental results reveal a direct correlation between flow rate and dimensional fidelity, while powders with higher shape factors (closer to spherical) exhibit improved flowability and uniform spreading. Post-sintering analysis was conducted to examine density, shrinkage, porosity, and mechanical strength. Graphical data are presented to illustrate relationships such as shape factor vs. angle of repose, flow rate vs. print accuracy, and sintering temperature vs. final part density. The findings provide a comprehensive understanding of how powder characteristics and digital process control can be leveraged to enhance the precision and quality of 3D-printed alumina ceramics.

Keywords: Angle of repose, shape factor, shrinkage