High green density ceramic components fabricated by the slurry-based 3DP process

Abstract

The 3DP process has been modified to directly fabricate high green density parts using
\nsubmicron powder. The slurry-based 3DP process deposits the powder bed by spraying a
\ndispersed slurry of the component material onto a piston. Alumina, silicon nitride, and
\nlead zirconate titanate components with green densities as high as 67% have been
\nfabricated by the slurry-based 3DP process. Solution phase binder systems have proven
\nto be successful for the new process. Substantially improved surface finish over the
\nconventional dry powder-based 3DP process has been demonstrated. Layer heights less
\nthan 50 Jlm can be prepared with this process. Thus, the stepped surface topography
\ncommonly observed in solid free form parts is substantially reduced.