Parameter Optimization for Printing Barium Titanate Piezoelectric Ceramics through Digital Light Processing

3D printing of piezoelectric ceramics is a growing field with potential for custom sensor fabrication. Prior research has shown that digital light processing (DLP) can produce complex ceramic structures. However, no prior work had resolved the precise parameter settings needed for high-performance barium titanate devices. Existing methods often result in inconsistent material properties due to unoptimized printing and post-processing conditions. The lack of standardized protocols for ceramic slurry composition and heat treatment remains a limitation. This gap motivated the current investigation into parameter optimization for DLP-based ceramic printing. Researchers have not yet determined the ideal powder content for stable printing and high piezoelectric output. The need for reproducible and scalable manufacturing methods drives this study.

This study aimed to optimize the DLP printing process for barium titanate ceramics. The specific problem addressed is the variability in printed part performance due to uncontrolled process parameters. The motivation stems from the need for reliable and high-quality piezoelectric devices. Previous approaches lacked systematic evaluation of slurry composition and heat treatment profiles. The researchers sought to identify optimal conditions for ceramic slurry formulation. They also aimed to determine the best heating rates for degreasing, carbon removal, and sintering. The study focused on achieving a high piezoelectric constant through controlled poling conditions. The ultimate goal was to produce functional sensors with consistent performance.

The researchers used a DLP 3D printing system to fabricate barium titanate samples. They prepared a ceramic slurry with 75 wt% powder content for printing. The printed green bodies underwent a controlled heat treatment process. Degreasing was performed at a heating rate of 4 °C/min. Carbon removal was also carried out at 4 °C/min. Sintering was conducted at a slower rate of 2 °C/min. The samples were then polarized using a poling field of 10 kV/cm. Poling time and temperature were set at 50 min and 60 °C, respectively. The printed parts were tested for piezoelectric performance and sensor functionality.

The optimized process produced barium titanate devices with a piezoelectric constant of 211 pC/N. The 75 wt% powder content in the slurry ensured good printability and structural integrity. The degreasing and carbon-removing steps at 4 °C/min prevented cracking and deformation. A slower sintering rate of 2 °C/min improved densification and microstructure. The poling conditions of 10 kV/cm, 50 min, and 60 °C yielded strong polarization. The resulting parts demonstrated high sensitivity as force sensors. They also showed reliable performance as magnetic sensors. The study confirmed the feasibility of DLP for producing functional piezoelectric ceramics.

The study demonstrated that DLP can be used to manufacture high-performance barium titanate ceramics. The optimized parameters led to a piezoelectric constant of 211 pC/N. The 75 wt% powder content in the slurry was essential for stable printing. The heating rates during degreasing and carbon removal were critical for structural integrity. A slower sintering rate improved the final microstructure and mechanical properties. The poling conditions significantly influenced the piezoelectric output. The researchers validated the use of the printed parts as functional sensors. The findings suggest that the optimized process can be applied to other piezoelectric materials.