Flexures are vital in precision engineering for frictionless, repeatable motion. While metallic fexures are common, ceramics offer higher stifness, thermal stability, low density, and environmental compatibility. Stereolithography-based ceramic additive manufacturing enables such designs, but qualifcation is hindered by manufacturability, reliability, and integration challenges. A mapping of over 180 manufactured fexure geometries identified aspect-ratio driven defect modes—cracking, delamination, cleaning failures, and warping. From these results, a defect identification map and a flexure design space chart were developed, providing generalized guidance on geometric limits for ceramic AM across platforms. Four-point bending of flexure specimens, whose geometry is representative of exure mechanism designs, yielded strengths of 158.6 MPa (β = 5.3) for alumina and 669.5 MPa (β = 6.1) for zirconia. Dynamic sweeps measured natural frequencies of 7.3 kHz (alumina) and 5.1 kHz (zirconia), within 5% of fnite element predictions. Resonance-based fatigue testing demonstrated endurance, with both materials sustaining 60 MPa loads for > 6×10^9 cycles without resonance drift. A dual-mode bonding strategy addressed build and sintering constraints: UVcurable green bonding produced assemblies with face–edge joints retaining 60.6% of monolithic strength (137.5 MPa, β = 6.57), while dry-contact spacers reduced distortion from 1 mm to below measurement resolution.
