Particle stereolithography

A method for the stereolithographic fabrication of a three-dimensional object as a plurality of successive layers, comprising the steps of:

• providing a layer of resin, wherein the resin includes a first binder having a melt temperature, a second binder that is immiscible in the first binder and which crosslinks or polymerizes upon sufficient exposure to light of a predetermined wavelength, and at least one of ceramic particles and metal particles, wherein the resin has a temperature above the melt temperature of the first binder;
• exposing a portion of the layer of resin to a pattern of light from a light source to cure the portion of the layer of resin into one of the plurality of the successive layers by curing the second binder without curing the first binder;
• repeating the steps of providing a layer of resin and exposing a portion of the layer of resin to a pattern of light to form a green form of the three-dimensional;
• conducting a first debinding process to debind the first binder, wherein during the first debinding process the first binder is at a temperature above the melt temperature;
• conducting a second debinding process to debind the second binder;
• and
• thermally processing the green form of the three-dimensional object until the at least one of ceramic particles and metal particles densify to a finished form of the three-dimensional object.