Microfabrication of ceramics by rapid prototyping process chains

Abstract

Most shaping processes for ceramics are based on a powder technological moulding process using a negative mould and subsequent thermal compaction. Especially for prototypes and small-lot series of microcomponents, the outlay for moulds is the major costing factor. Therefore the use of rapid prototyping (RP) processes can decisively reduce the costs and time in product development of ceramic microcomponents. By combining the high resolution of, for example, stereolithography as an inexpensive and fast supply for master models with the high flexibility of low-pressure injection moulding, a rapid prototyping process chain (RPPC) has been established for the fabrication of micropatterned ceramic components as functional models or pre-production lots. This RPPC proved to have a very high moulding precision and accuracy in the submillimetre range, but also enables the fabrication of components with outer dimensions of several centimetres. Different RP techniques were investigated with regard to their suitability to be used as master models in the replication chain. The quality of the master models turned out to be of decisive significance for the quality and reproducibility of the ceramic mouldings.