A review of dispersing strategies for aluminum nitride suspensions in vat photopolymerization systems

Abstract

Aluminum nitride (AlN) is a key ceramic material for thermal management applications due to its high thermal conductivity and electrical insulation. However, processing AlN via vat photopolymerization (VPP) remains challenging, as highly loaded suspensions must exhibit low viscosity, stable dispersion, and adequate curing behavior. This review analyzes dispersing strategies for stabilizing AlN suspensions in VPP systems. Different classes of additives are examined, including small-molecule surfactants, silane coupling agents, polymeric dispersants, and industrial dispersant systems. Their influence on particle stabilization mechanisms, slurry rheology, curing behavior, and achievable solid loading is discussed. In addition, the role of resin composition, including monomer functionality and refractive index, is evaluated in relation to curing performance. The review highlights the transition from single-component dispersants to multifunctional formulation strategies combining surface modification, polymeric stabilization, and optimized resin design and provides guidelines for developing stable, high-solid-loading AlN suspensions for additive manufacturing.