In this paper, the gelcasting process of silicon carbide and boron carbide ceramics with big.size and complex shape are presented. The main concern is to develop a reliable process to produce homogeneous, crack free gelcasting samples. This is based on the understanding of interactions among components, the optimization of the slurry rheological properties and preventing the obvious settling of ceramic powder before gelation. The green samples with high bending strength and green density as well as homogeneous microstructure were realized. Subsequently, the optimized sintering process was also proposed for obtaining high performance ceramics with effective control of the deformation or warping during sintering. The microstructure development and resulting properties of green and final sintered sample were studied.
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