Rapid prototyping technique for ceramic mini-devices containing internal channels with asymmetrical contour

The electrophoretic deposition (EPD) is used to serve as rapid prototyping technology (RPT) to manufacture ceramic mini-devices containing internal channels or asymmetrical contour patterns to overcome the technical obstacles by conventional ceramic forming techniques. The spacing and geometry of such internal channels, either liner, curvilinear, symmetrical or asymmetrical, can be considered at the preliminary design stage to prepare the fugitive inactive inserts to be involved in EPD operations. Such inserts are limited to any undesirable chemical reaction with the EPD suspension and of easy elimination from EPD-formed ceramic green body followed by pyrolysis or solvent dissolution to remove from embedment. In this study, ferroelectric ceramic mini-devices based on barium titanate with the pattern containing internal channels was deposited via EPD route unto electrically conducting or non-conducting inserts buried in the ceramic laminates. The inserts can be removed after drying step. Effects of EPD conditions on shape integrity of internal channel in the mini-devices were examined. This novel ceramic shaping technique enables us to produce the ceramic mini-devices in terms of formation of desirable array patterns for the unique prototype of ceramic components such as dielectric resonators, waveguide or mini-actuators.