Mold-free, benchtop green machining of self-standing doughs of advanced ceramics

In product design, when we need long-term use, high thermal stability, high strength, and resistance to chemicals, we usually end up in the region that is covered by ceramics. On the other hand, these properties that single out ceramics for "extreme applications", are obstacles to conventional manufacturing methods. Currently, we do not have cost- and energy-effective, standard processing routes for ceramics that utilize existing setups for rapid prototyping and manufacturing in low numbers. Therefore, most of the time the frequent outcome is settling for either a sub-optimal material or shape. There is a clear need for alternative methods that are specifically designed for establishing standard manufacturing schemes for custom-based design and manufacturing in low numbers as well as cutting down the requirements of energy and capital investment in the ceramics industry.
We generate self-standing formulations of advanced ceramics. Starting from a self-standing structure that can withstand machining forces eliminates the need for a mold and enables near-net shaping at the green state. The additive content in these formulations is less than 2 wt. %; the formulation can be reused, and the products reach 99.5–99.9% of the theoretical density after sintering. This “no-material leak” process utilizes existing manufacturing setups and offers an unprecedented, cost-effective scheme for mold-free, low-number production. Throughout the project, the students will develop doughs of various advanced ceramics and carry out the processing steps to expand the realms of this methodology.