• Achieved silica-based ceramic core slurries with solid loading up to 68 vol.% by optimizing monomer ratio and dispersant content, overcoming viscosity limitations.
• Optimal slurry formulation (monomer mass ratio 3:2, 4 wt.% BYK111) exhibited superior curing and rheological performance, enabling high-quality VPP 3D printing.
• Increasing solid loading led to denser microstructure and improved flexural strength (19.5 MPa), while sintering shrinkage became more uniform, meeting casting requirements.
• Provides a practical guide for preparing high solid loading ceramic slurries, advancing the fabrication of complex ceramic cores for aero-engine applications.