Aquacasting is a new tape casting process using UV curable latex dispersions as a matrix for the shaping of aqueous based ceramic slurries, applicable for both homogenous structures as well as for the preparation of layered structures. In this work the influence of additives and solid load on the processing and final properties of the porous material using zirconia is studied. The impact of these additives on rheology, curing behavior, debinding and sintering as well as the thermal conductivity of the sintered material is presented.